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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of provisional patent application Ser. No. 60/890,560, filed 2007 Feb. 19 by the present inventors.
FEDERALLY SPONSORED RESEARCH
Not Applicable.
SEQUENCE LISTING OR PROGRAM
Not Applicable.
BACKGROUND OF THE INVENTION
1. Field of Invention
The present application relates generally to a device for removing lint and other debris from clothing and the like. In particular, the application relates to a handheld disposable sheet, or patch, for removing lint and other debris from clothing and the like.
2. Prior Art
Clothing and other fabric covered articles, such as chairs, couches, and the like, have a tendency to collect or attract lint. As used herein, the term “lint” refers to fibers from both natural and/or synthetic sources, including hair from any animal, and any natural and/or synthetic particles and/or particulate matter, and the like, as well as dust, other debris, and the like.
Lint is considered an undesirable item when attached to clothing or other fabric covered articles. Due to its undesirable nature individuals are in need of easy and inexpensive methods of removing lint from clothing and other fabric covered articles. The knowledge of lint's undesirable nature has caused inventors to seek several ways to remove lint once it has become attached to clothing and other fabric covered items.
Inventors have done a commendable job of inventing several methods through which lint may be removed from clothing and other fabric covered items. However, the known prior art devices for removing lint include lint rollers, lint mitts, lint brushes and other bulky or cumbersome devices can not meet the needs of all individuals.
The lint roller with a tab, U.S. Pat. No. 6,954,953 to McKay and the lint brush U.S. Pat. No. 7,107,634 to McKay and all other similar lint removal devices are large and bulky devices taking up relatively large amounts of space. The amount of space discourages individuals from carrying this product with them. The failure to easily carry these items is a detriment to individuals who wish to have a lint removal device on their person at all times.
The lint mitt, U.S. Pub. No. 2002/0124335 μl to Franko, Sr. and LINT GLOVE, U.S. Pat. No. 6,024,970 to Woodward are more compact lint removal devices than the aforementioned lint roller and lint brush, but are not without their drawbacks. These devices both require a user to insert their hand or a portion thereof to effectively utilize the device. The requirement that a user insert their hand into the device both increases production costs and the likelihood the product will tear or otherwise become unusable through common use.
The DISPOSABLE LINT REMOVER disclosed in U.S. Pat. No. 5,894,623 describes a device that is less bulky and more portable than the preceding devices. Although less bulky and more portable, the DISPOSABLE LINT REMOVER requires the user to insert two fingers into thin tabs which will allow the user to grasp the apparatus. This design suffers from many of the same downfalls of the LINT GLOVE and lint mitt in that it requires a component that must be made of thin material yet must survive the handling by fingers of various sizes and strengths.
There are several types of lint removal apparatuses available for review, but all the known available apparatuses suffer from a number of disadvantages. These disadvantages either make the apparatus costly to produce, difficult to transport or subject to undue breakage.
BRIEF SUMMARY
This invention seeks to distinguish itself from the prior art by providing several advantages over the prior art while accomplishing several objectives. This invention is an invention that will provide useful benefits above and beyond those currently available.
This major advantage of this invention is that the device is readily portable. This invention is capable of easily being placed into a shirt pocket, pants pockets or likewise taking up little space in a briefcase, purse or other similar device. The product is also capable of being placed into a wallet for easy transport. Due to its size users will also be able to easily carry more than one Lint Patch with them at any given time. While retaining this portability and compact feature, the invention still provides a small tab that can serve as a handle during its use.
The next significant advantage of the invention is its durability. Although a disposable product durability is important for the transport and use of the invention. The invention has no additional components, compartments, accessories, attachments or gripping devices that could easily be damaged and render the invention unusable. The invention's durability will allow it to ready and available for use under almost all circumstances.
Another advantage to the invention is that it can be used by individuals without regard to hand size or strength. This invention, unlike the aforementioned lint glove or lint mitt inventions, does not have limitations that can be attributed to the end users personal characteristics. A small hand or a large hand will be equally capable of using this invention without causing any damage to the product as may occur with the use of the lint glove or the lint mitt. These limitations are removed because instead of utilizing compartments or tabs for the user to grip, the adhesive side of the invention will retain a non-adhesive portion whereby the invention may be held during its use.
Further possible advantages to the invention are that the backing used to protect the adhesive before use may be saved and reapplied to the invention. This reapplication of the backing can allow for the invention to be used more than once by an end user. The invention will also be inexpensive to produce as it does not require any special attachments or gripping devices in order for the invention to be used. The invention can also be made to have customized imprinting on it to provide for additional sales and marketing opportunities.
In conclusion the invention provides for a durable, economical, easily portable and easy to use apparatus with a tabbed gripping area which an individual may utilize to remove lint from clothing or other fabric covered articles.
BRIEF DESCRIPTION OF THE DRAWINGS
It will be appreciated that the illustrated boundaries of elements (e.g., boxes or groups of boxes) in the figures represent one example of the boundaries. One of ordinary skill in the art will appreciate that one element may be designed as multiple elements or that multiple elements may be designed as one element. Further, in the accompanying drawings and description that follow, like parts are indicated throughout the drawings and description with the same reference numerals, respectively. The figures may not be drawn to scale and the proportions of certain parts have been exaggerated for convenience of illustration.
FIG. 1 is a front planar view of one embodiment of a lint patch having a tab;
FIG. 2 is a front planar view of one embodiment of a lint patch with a backing partially removed;
FIG. 3 is a simplified close-up side view of one embodiment of a lint patch;
FIG. 4 is a front view of one embodiment of a lint patch, held by an exemplary user;
FIG. 5 is a front planar view of an alternative embodiment of a lint patch having a tab on an upper right corner;
FIG. 6 is a front planar view of an alternative embodiment of a lint patch having a tab on a right side;
FIG. 7 is a front planar view of an alternative embodiment of a lint patch having a tab on a lower left corner;
FIG. 8 is a front planar view of an alternative embodiment of a lint patch having a tab on an upper left corner;
FIG. 9 is a front planar view of an alternative embodiment of a lint patch having a tab on a left side;
FIG. 10 is a front planar view of an alternative embodiment of a lint patch having a pair of tabs on a lower right corner and a lower left corner;
FIG. 11 is a front planar view of an alternative embodiment of a lint patch having a pair of tabs, with a backing partially removed;
FIG. 12 is a front planar view of an alternative embodiment of a lint patch having a pair of tabs on a right side and a left side;
FIG. 13 is a front planar view of an alternative embodiment of a lint patch having a pair of tabs on an upper right corner and an upper left corner;
FIG. 14 is a front planar view of an alternative embodiment of a lint patch having a curved perforation;
FIG. 15 is a front planar view of an alternative embodiment of a lint patch having a curved perforation, with a backing partially removed; and
FIG. 16 is a front planar view of an alternative embodiment of a lint patch having a curved perforation, with a backing removed.
DETAILED DESCRIPTION
FIG. 1 shows a front planar view of one embodiment of a lint patch 100 . In the illustrated embodiment, the lint patch 100 includes a sheet 110 and a tab 120 . The sheet 110 is generally square with rounded corners. In an alternative embodiment (not shown), the sheet may have sharp corners. In other alternative embodiments (not shown), the sheet may be rectangular, circular, oval, or have the shape of any regular or irregular polygon.
The tab 120 is configured to be grasped by a user's thumb and/or fingers. In the illustrated embodiment, the tab 120 is located at the bottom right corner of the sheet 110 and extends approximately ⅓ the length of the sheet 110 . In alternative embodiments (not shown), the tab 120 may have a length that is approximately 5% of the length of the sheet to approximately 150% of the length of the sheet. In an alternative embodiment (not shown), a loop or a ring of material may be used in place of a tab.
FIG. 2 illustrates a front planar view of the lint patch 100 , having a backing 210 partially removed to expose an adhesive surface 220 . The backing 210 includes a non-stick surface, allowing it to be peeled from the adhesive surface 220 . In the illustrated embodiment, the adhesive surface 220 and the backing 210 extend across the entire sheet 110 , but neither the adhesive surface 220 nor the backing 210 extend to the tab 120 . In an alternative embodiment (not shown), only a portion of the sheet (i.e., less than 100%) is covered by the adhesive surface 220 and the backing 210 . For example, a border may extend around the edges of the sheet 110 to allow a user to handle the edges of the lint patch 100 . In another alternative embodiment (not shown), the adhesive surface 220 and the backing 210 extend across the tab 120 .
In one embodiment (not shown), the adhesive surface is scented, so that the lint patch 100 may serve dual functions of removing lint and providing a pleasing scent to clothing, furniture, and other objects.
FIG. 3 illustrates a cross-section of one embodiment of the sheet 110 . In one embodiment, the sheet 110 has a thickness of about 0.01 inches to about 0.1 inches. In an alternative embodiment, the sheet 110 has a thickness of about 0.002 inches to about 0.5 inches. In the illustrated embodiment, the sheet 110 includes the backing 210 having a release coating 310 provided thereon. The backing 210 may be constructed of paper, cardboard, or other similar material. In an alternative embodiment (not shown), the release coating 310 is impregnated into the backing 310 to form an overall “release backing” having a unitary construction.
With continued reference to FIG. 3 , the sheet 110 further includes a face sheet 320 having an adhesive provided thereon to form the adhesive surface 220 . In one embodiment, the adhesive may be a full-coat pressure-sensitive face.
As is known to those skilled in the art, release coating 310 functions to allow removal or “peel off” of backing 210 from the sheet 110 , for exposure of the adhesive surface 220 as desired. Adhesive laminate is commercially available in roll form from, for example, Green Bay Packaging Inc.—Coated Products Operations of Green Bay, Wis., and from Avery Dennison Corporation of Pasadena, Calif.
FIG. 4 illustrates one embodiment of a lint patch 100 in use by an exemplary user. In the illustrated embodiment, the user holds the lint patch 100 with his right hand H. The tab 120 extends beneath the thumb of the user's hand H. The user may grasp the tab 120 by squeezing it between the thumb and the forefinger of the right hand H. It should be understood that the lint patch 100 may be rotated 180 degrees, such that the tab 120 extends from the upper left corner of the sheet 110 instead of the lower right corner. In this orientation, the lint patch 100 may be grasped by the left hand of the user, with the tab extending behind the thumb of the user's left hand.
In the illustrated embodiment, the user has removed the backing from the sheet 110 to expose the adhesive surface 220 . The user may then remove lint, hair, dirt, or other loose material from an article of clothing, furniture, or other objects, by pressing the adhesive surface 220 of the sheet 110 against the object, then lifting the lint patch 100 . The user may use a brushing or a patting motion to achieve lint removal.
In one embodiment, before the backing 210 is removed from the lint patch 100 , the lint patch 100 may be easily transported in a user's pocket, purse, briefcase, or other such location. Alternatively, the lint patch 100 may be stored in a closet, drawer, chest, trunk, shelf, or other such location. For example, in one embodiment, a plurality of lint patches may be joined together in a continuous tape, with the boundaries of each lint patch defined by perforations. In this embodiment, the continuous tape may be wound in a roll for storage. The roll may be stored in a dispenser.
In an alternative embodiment, a plurality of lint patches may be stacked on top of each other, or next to each other, for bulk storage or transportation. The stack of lint patches may be stored in a dispenser. In one embodiment, the lint patches may have tabs different locations to facilitate the removal of a single lint patch from the sheet.
For example, FIG. 5 illustrates an alternative embodiment of a lint patch 500 having a sheet 510 and a tab 520 extending from the upper right corner of the sheet. It should be understood that the lint patch 500 otherwise has the same features as those described above in relation to the lint patch 100 illustrated in FIGS. 1-4 .
FIG. 6 illustrates another alternative embodiment of a lint patch 600 . In this embodiment, the lint patch 600 has a sheet 610 and a tab 620 extending from a central portion of the right side of the sheet. It should be understood that the lint patch 600 otherwise has the same properties as those described above in relation to the lint patch 100 illustrated in FIGS. 1-4 .
In one embodiment, to facilitate easy removal of a single lint patch, a stack of lint patches may alternate between a lint patch 100 having a tab 120 extending from a lower right corner of the sheet 110 , followed by a lint patch 600 having a tab 620 extending from a central portion of the right side of the sheet 610 , followed by a lint patch 500 having a tab 520 extending from the upper right corner of the sheet 510 . It should be understood, however, that the lint patches may be stacked in any desired order.
FIGS. 7-9 illustrate additional alternative embodiments of lint patches configured to be grasped by a user's left hand (not shown). FIG. 7 illustrates an alternative embodiment of a lint patch 700 having a sheet 710 and a tab 720 extending from a lower left corner of the sheet 710 . It should be understood that the lint patch 700 otherwise has the same properties as those described above in relation to the lint patch 100 illustrated in FIGS. 1-4 . It should be further understood that the lint patch 700 may be structurally identical to the lint patch 500 illustrated in FIG. 5 , but rotated 180 degrees.
FIG. 8 illustrates an alternative embodiment of a lint patch 800 having a sheet 810 and a tab 820 extending from an upper left corner of the sheet 810 . It should be understood that the lint patch 800 otherwise has the same properties as those described above in relation to the lint patch 100 illustrated in FIGS. 1-4 . It should be further understood that the lint patch 800 may be structurally identical to the lint patch 100 , but rotated 180 degrees.
FIG. 9 illustrates an alternative embodiment of a lint patch 900 having a sheet 910 and a tab 920 extending from a central portion of the left side of the sheet 910 . It should be understood that the lint patch 900 otherwise has the same properties as those described above in relation to the lint patch 100 illustrated in FIGS. 1-4 . It should be further understood that the lint patch 900 may be structurally identical to the lint patch 600 illustrated in FIG. 6 , but rotated 180 degrees.
FIG. 10 illustrates an alternative embodiment of a lint patch 1000 configured to be grasped by a user's right or left hand without the need to rotate the lint patch 1000 . In the illustrated embodiment, the lint patch 1000 includes a sheet 1010 , a first tab 1020 extending from the lower right corner of the sheet 1010 , and a second tab 1030 extending from the lower left corner of the sheet 1010 . The sheet 1010 is generally square with rounded corners. In an alternative embodiment (not shown), the sheet may have sharp corners. In other alternative embodiments (not shown), the sheet may be rectangular, circular, oval, or have the shape of any regular or irregular polygon.
The tab 1020 is configured to be grasped by a user's right thumb and/or fingers when the lint patch 1010 is held by a right hand. When the lint patch 1010 is held by a user's left hand, the tab 1020 may be grasped between a user's left pinky finger and left ring finger, or it may simply be left free. In the illustrated embodiment, the tab 1020 is located at the bottom right corner of the sheet 1010 and extends approximately ⅓ the length of the sheet 1010 . In alternative embodiments (not shown), the tab 1020 may have a length that is approximately 5% of the length of the sheet to approximately 150% of the length of the sheet. In an alternative embodiment (not shown), a loop or a ring of material may be used in place of a tab.
The tab 1030 is configured to be grasped by a user's left thumb and/or fingers when the lint patch 1010 is held by a left hand. When the lint patch 1010 is held by a user's right hand, the tab 1030 may be grasped between a user's right pinky finger and right ring finger, or it may simply be left free. In the illustrated embodiment, the tab 1030 is located at the bottom left corner of the sheet 1010 and extends approximately ⅓ the length of the sheet 1010 . In alternative embodiments (not shown), the tab 1030 may have a length that is approximately 5% of the length of the sheet to approximately 150% of the length of the sheet. In an alternative embodiment (not shown), a loop or a ring of material may be used in place of a tab.
FIG. 11 illustrates a front planar view of the lint patch 1000 , having a backing 1110 partially removed to expose an adhesive surface 1120 . The backing 1110 includes a non-stick surface, allowing it to be peeled from the adhesive surface 1120 . In the illustrated embodiment, the adhesive surface 1120 and the backing 1110 extend across the entire sheet 1010 , but neither the adhesive surface 1120 nor the backing 1110 extend to the tabs 1020 , 1030 . In an alternative embodiment (not shown), only a portion of the sheet is covered by the adhesive surface 1120 and the backing 1110 . For example, a border may extend around the edges of the sheet 1010 to allow a user to handle the edges of the lint patch 1000 . In another alternative embodiment (not shown), the adhesive surface 1120 and the backing 1110 extend across the tabs 1020 , 1030 .
FIG. 12 illustrates another alternative embodiment of a lint patch 1200 . In this embodiment, the lint patch 1200 has a sheet 1210 , a first tab 1220 extending from a central portion of the right side of the sheet 1210 , and a second tab 1230 extending from a central portion of the left side of the sheet 1210 . It should be understood that the lint patch 1200 otherwise has the same properties as those described above in relation to the lint patch 1000 illustrated in FIGS. 10-11 .
FIG. 13 illustrates another alternative embodiment of a lint patch 1300 having a sheet 1310 , a first tab 1320 extending from the upper right corner of the sheet 1310 , and a second tab 1330 extending from the upper left corner of the sheet 1310 . It should be understood that the lint patch 1300 otherwise has the same properties as those described above in relation to the lint patch 1000 illustrated in FIGS. 10-11 . It should be further understood that the lint patch 1300 may be structurally identical to the lint patch 1000 , but rotated 180 degrees.
FIG. 14 illustrates another alternative embodiment of a lint patch 1400 having sheet 1410 and a curved perforation defining a tab 1420 . In prior illustrated embodiments, the lint patches were shown to have tabs defined by a straight perforation. It should be understood that the tab may take any desired shape.
FIG. 15 illustrates a front planar view of the lint patch 1400 , having a backing 1510 partially removed to expose an adhesive surface 1520 . The backing 1510 includes a non-stick surface, allowing it to be peeled from the adhesive surface 1520 . In the illustrated embodiment, the adhesive surface 1520 and the backing 1510 extend across the entire sheet 110 , but neither the adhesive surface 1520 nor the backing 1510 extend to the tab 1520 . In an alternative embodiment (not shown), only a portion of the sheet is covered by the adhesive surface 1520 and the backing 1510 . For example, a border may extend around the edges of the sheet 1410 to allow a user to handle the edges of the lint patch 1400 .
FIG. 16 illustrates a front planar view of the lint patch 1400 , with the backing completely removed to expose the adhesive surface 1520 . In the illustrated embodiment, the tab 1420 has a rectangular shape, with rounded corners. In one embodiment, the tab is shaped to provide a non-stick surface for a user to grasp, while maximizing the size of the adhesive surface 1520 .
To the extent that the term “includes” or “including” is used in the specification or the claims, it is intended to be inclusive in a manner similar to the term “comprising” as that term is interpreted when employed as a transitional word in a claim. Furthermore, to the extent that the term “or” is employed (e.g., A or B) it is intended to mean “A or B or both.” When the applicants intend to indicate “only A or B but not both” then the term “only A or B but not both” will be employed. Thus, use of the term “or” herein is the inclusive, and not the exclusive use. See, Bryan A. Garner, A Dictionary of Modem Legal Usage 624 (2d. Ed. 1995). Also, to the extent that the terms “in” or “into” are used in the specification or the claims, it is intended to additionally mean “on” or “onto.” Furthermore, to the extent the term “connect” is used in the specification or claims, it is intended to mean not only “directly connected to,” but also “indirectly connected to” such as connected through another component or multiple components.
While the present application illustrates various embodiments, and while these embodiments have been described in some detail, it is not the intention of the applicant to restrict or in any way limit the scope of the claimed invention to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention, in its broader aspects, is not limited to the specific details and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's claimed invention. Moreover, the foregoing embodiments are illustrative, and no single feature or element is essential to all possible combinations that may be claimed in this or a later application.
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A lint removal apparatus containing a tabbed end or ends on any side so a user to grip and hold the apparatus. One side of the apparatus contains an adhesive side that is protected by a backing. The backing must be removed by the user prior to using the apparatus. Once the backing is removed, a small portion of the backing will remain so that user can easily grip the apparatus. While gripping the apparatus, the user may remove lint by pressing the exposed adhesive side of the apparatus against the desired area containing lint or other particles to be removed. The apparatus is a small, durable, portable, economic, practical and be used by all individuals regardless of physical size.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 12/708,088, entitled “Thermodynamic Power Generation System” filed on Feb. 18, 2010, which in turn claims the benefit of the filing date of U.S. Provisional Patent Application No. 61/154,020, filed on Feb. 20, 2009, the entire contents of which are herein incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to externally heated engines. More particularly the invention relates to improvements in efficiency and performance of externally heated engines operating at low temperatures and pressures.
BACKGROUND OF THE INVENTION
[0003] Externally heated engines especially those similar to the gas or liquid turbine type engines have always held great promise. This is because such engines are reasonably efficient, relatively simple in their operation, and flexible in the media they can employ as working fluids. At the same time however, they have been held back in many applications by certain serious limitations.
[0004] Turbine style engines that employ liquid fluid flows are the most limited. Unless one has access to a dam, with a large head of water behind it, or a particularly rapidly flowing stream with a large drop in elevation, one cannot produce significant amounts of power. Without a dam or a stream it is simply not feasible or efficient to heat the liquid sufficiently, or to pump it uphill far enough and cheaply enough, to obtain a useful net output. Similarly, a paddle wheel type structure such as found on certain steam ships for instance, require a separate source of motive power, such as a steam engine, to operate them.
[0005] Turbine type engines that employ flows of a gaseous fluid hold more promise. It is practical to employ fluids in the gas phase to power engines, as in steam locomotives for example. Other types of hot gas turbines are also well known in the prior art, and can operate effectively. In virtually all of these cases however, the required temperatures and pressures to which the gas must be raised are very high. It is not uncommon for such engines to reach temperatures of hundreds of degrees Fahrenheit, and at the same time to operate at pressures of hundreds of PSI. In general, this means that a source of combustion must be specifically provided and operated in conjunction with the engine, for the sole benefit of the engine, in order to reach the operating levels required.
[0006] Old style steam locomotives and stationary steam engines for instance ran on large coal fires, operating in conjunction with pressure-raising pumps, to produce the required levels. Such engines were well known for exploding at inopportune times.
[0007] Gas turbine engines, such as those used at electrical generation stations, also employ very high temperatures and pressures. Jet turbine engines, such as those employed on aircraft, also produce extremely high temperatures in their combustion chambers, and they further employ multiple stages of compression to reach the desired pressures and temperatures.
[0008] The present invention is directed to a heat engine and power generating system that avoids high temperatures and pressure and relies instead on relatively low temperature heat sources and low pressure operating fluids to generate energy. The system will function without the need for our own dedicated source of combustion in order to operate and will operate at a relatively high efficiency, and produce significant amounts of power. The engine is designed to operate on low temperature waste heat left over from other processes, or to operate on low temperature solar, geothermal power, power plant waste heat, or waste heat available from air conditioning or refrigeration units or for instance.
DESCRIPTION OF THE PRIOR ART
[0009] The configuration of turbine power plants including in particular the turbine blades on a rotating member, the housing construction and the working fluid inlet and exhaust ports have been the subject of many prior art patents.
[0010] U.S. Pat. No. 3,501,249 to Scalzo, is directed to turbine rotors and particularly to structure for locking the turbine rotor blades in the periphery of the blade supporting disk.
[0011] U.S. Pat. No. 4,073,069 to Basmajian discloses an apparatus comprising a turbine rotor wheel made of a central circular disc with arc-bent plate turbine blades mounted on and bonded to the disc at close and regular intervals around the disc periphery and a stator-housing with a transparent cover for enclosing the turbine wheel, holding one or more feed nozzles and providing a stator reaction mount for the nozzles, the wheel and its housing being mounted from an instrument chassis containing parameter adjusting means and turbine output adjusting and measuring means to provide a compact, economical demonstrator of turbine operation.
[0012] U.S. Pat. No. 4,400,137 to Miller et al discloses a rotor assembly and methods for securing rotor blades within and removing rotor blades from rotor assemblies. The rotor assembly comprises a rotor disc defining a plurality of blade grooves, and including a plurality of tenons disposed between the blade grooves and defining a plurality of pin sockets radially extending inward from outside surfaces of the tenons; and a plurality of rotor blades, each blade including a root disposed within a blade groove to secure the blade against radial movement, and a blade platform overlaying a tenon and defining a radially extending pin aperture. The rotor assembly further comprises a plurality of locking pins radially extending through the pin apertures and into the pin sockets to secure the rotor blades against axial movement, each pin including a head and a base to limit radial movement of the pin.
[0013] U.S. Pat. No. 4,421,454 to Wosika discloses a full admission radial impulse turbine and turbines with full admission radial impulse stages. The turbines are of the single shaft, dual pressure type. Provision is made for utilizing working fluid exhausted from the high pressure section, in which the radial impulse stage(s) are located, in the low pressure section which contains axial flow turbine stages. The (or each) radial impulse stage in the dual pressure turbine has a rotor or wheel with buckets or pockets oriented transversely to the direction of wheel rotation and opening onto the periphery of the wheel. Working fluid is supplied to the buckets via nozzles formed in, or supported from, a nozzle ring surrounding the turbine wheel and aligned with the entrance ends of the buckets.
[0014] U.S. Pat. No. 4,502,838 to Miller et al discloses buckets of a turbine wheel that are formed as a series of equally spaced, overlapping U-shaped passages in the rim of a wheel blank. In the machining operation, an island is left as the inner segment of the curved portion of the U and this is used in combination with labyrinth seals to provide a fluid seal between the inlet and the outlet portion of each bucket.
[0015] U.S. Pat. No. 5,074,754 to Violette discloses a retention system for a rotor blade that utilizes the combination of a fixed retention flange and a removable retention plate with a closed-sided retention member. This system enables the rapid replacement or removal of the rotor blade for inspection, maintenance, or replacement purposes without requiring removal of surrounding major engine components or structural members. The rotor blade is installed in a retention member contained in a rotatable hub (not shown) by inserting an outwardly extending portion of a shaped blade root of the rotor blade below a radially-inwardly projecting shaped flange peripherally disposed within the interior of the retention member's structure. A removable shaped retention plate, which is releasably secured to, and adapted to mate with, the retention member, then captures and secures another outwardly extending portion of the shaped root of the rotor blade with a releasable fastener. The shaped root is secured within the retention member without a direct bolted connection. Preloading the fastener induces compressive loading among the system components, resulting in the attenuation or elimination of fretting and wear of their respective component surfaces.
[0016] The prior art includes many examples of power systems that attempt to capture waste heat from a primary heat source and reuse the energy in a secondary power system.
[0017] U.S. Pat. No. 3,822,554 to Kelly discloses a heat engine operating between temperatures T 1 (low) and T 2 (high) includes separate vapor closed-cycle motor and pump systems, in heat-exchange relation at T 1 and T 2 , and heat-exchangers between the condensates of said systems.
[0018] U.S. Pat. No. 3,953,973 to Cheng et al discloses a heat engine, or a heat pump, in which the working medium is subjected alternatively to solidification and melting operations. A working medium is referred to as an S/L type working medium that is subjected to cyclic operations, each cycle comprises of a high temperature melting step conducted under a first pressure, and a low temperature solidification step conducted under a second pressure. Each heat pump cycle includes a high temperature solidification step conducted under a first pressure and a low temperature melting step conducted under a second pressure. When a non-aqueous medium is used, the first pressure and the second pressure are a relatively high pressure and a relatively low pressure, respectively. When an aqueous medium is used the two pressures are a relatively low pressure and a relatively high pressure, respectively. The operation of a heat pump is the reverse operation of a heat engine.
[0019] U.S. Pat. No. 4,292,809 to Björklund discloses a procedure for converting low-grade thermal energy into mechanical energy in a turbine for further utilization. The procedure is characterized in that a low-grade heating medium and a first cooling medium are evaporated in a heat exchanger. The steam is carried to a turbine for energy conversion and moist steam is carried from here to a heat exchanger for condensing. The condensate is pumped back to the heat exchanger. The heat exchanger is common to the steam turbine circuit and a heat pump circuit in such a manner that the heat exchanger comprises a condenser for the steam turbine circuit and an evaporator in the heat pump circuit. The heat removed in connection with condensing can be absorbed by a second evaporating cooling medium the steam of which is pumped via a heat pump to a heat exchanger which is cooled by cooled medium from the heat exchanger and where condensing takes place. The condensate is carried via an expansion valve back to the heat exchanger while outgoing cooled medium from the heat exchanger is either heated in its entirety to a lower level than the original temperature at the commencement of the process or else a partial flow is reheated to a level that is equal to or higher than the original temperature at the commencement of the process and returned to the heat exchanger. The hot gas of the heat pump is used for extra superheating of the ingoing first evaporated cooling medium supplied to the turbine.
[0020] U.S. Pat. No. 4,475,343 to Dibelius et al discloses a method for the generation of heat using a heat pump in which a heat carrier fluid is heated by a heat exchanger and compressed with temperature increase in a subsequent compressor, heat is delivered therefrom to a heat-admitting process; the fluid is then expanded in a gas turbine, producing work, and afterwards its residual heat is delivered to a thermal power process, the maximum temperature of the energy sources of which, that provide work for the compressor, lies below the temperature of heat delivery. The main heat source can consist of an exothermic chemical or nuclear reaction and the heat-admitting process can be a coal gasification process. The work in the compressor is furnished essentially by the gas turbine and the thermal power process.
[0021] U.S. Pat. No. 4,503,682 to Rosenblatt discloses an engine system that includes a synthetic low temperature sink which is developed in conjunction with an absorbtion-refrigeration subsystem having inputs from an external low-grade heat energy supply and from an external source of cooling fluid. A low temperature engine is included which has a high temperature end that is in heat exchange communication with the external heat energy source and a low temperature end in heat exchange communication with the synthetic sink provided by the absorbtion-refrigeration subsystem. It is possible to vary the sink temperature as desired, including temperatures that are lower than ambient temperatures such as that of the external cooling source. This feature enables the use of an external heat input source that is of a very low grade because an advantageously low heat sink temperature can be selected.
[0022] U.S. Pat. No. 5,421,157 to Rosenblatt discloses a low temperature engine system that has an elevated temperature recuperator in the form of a heat exchanger having a first inlet connected to an extraction point at an intermediate position between the high temperature inlet and low temperature outlet of a turbine heat engine and an outlet connected by a conduit to a second inlet to the turbine between the high and low temperature ends thereof and downstream of the extraction point. In the recuperator thermodynamic medium vapor from extraction point is in heat exchange relationship with thermodynamic medium conducted from the low temperature exhaust end of the turbine unit through a water cooled condenser and in heat exchange relationship in a refrigerant condenser with a refrigerant flowing in an absorption-refrigeration subsystem. The thermodynamic medium leaving the recuperator for return to the turbine is conducted through return conduit in further heat exchange relationship with the refrigerant of the absorbent-refrigerant subsystem and is heated in a heat exchanger by an external source of heat energy and is returned to the high temperature end of the turbine through conduit to complete the cycle. External coolant, such as water, is conducted through the thermodynamic-medium condenser in heat exchange relation with the thermodynamic medium passing there through from the low temperature exhaust end of the turbine.
[0023] U.S. Pat. No. 5,537,823 to Vogel, discloses a combined cycle thermodynamic heat flow process for the high efficiency conversion of heat energy into mechanical shaft power. This process is particularly useful as a high efficiency energy conversion system for the supply of electrical power (and in appropriate cases thermal services). The high efficiency energy conversion system is also disclosed. A preferred system comprises dual closed Brayton cycle systems, one functioning as a heat engine, the other as a heat pump, with their respective closed working fluid systems being joined at a common indirect heat exchanger. The heat engine preferably is a gas turbine, capable of operating at exceptionally high efficiencies by reason of the ability to reject heat from the expanded turbine working fluid in the common heat exchanger, which is maintained at cryogenic temperatures by the heat pump system. The heat pump system usefully employs gas turbine technology, but is driven by an electric motor deriving its energy from a portion of the output of the heat engine.
[0024] U.S. Pat. No. 6,052,997 to Rosenblatt discloses an improved combined cycle low temperature engine system having a circulating expanding turbine medium that is used to recover heat as it transverses it turbine path. The recovery of heat is accomplished by providing a series of heat exchangers and presenting the expanding turbine medium so that it is in heat exchange communication with the circulating refrigerant in the absorption refrigeration cycle. Previously recovery of heat from an absorption refrigeration subsystem was limited to cold condensate returning from the condenser of an ORC turbine on route to its boiler.
[0025] U.S. Pat. No. 7,010,920 to Saranchuk et al discloses a low temperature heat engine that circulates waste heat back through a heat exchanger to the prime mover inlet. The patent discloses a method for producing power to drive a load using a working fluid circulating through a system that includes a prime mover having an inlet and an accumulator containing discharge fluid exiting the prime mover. A stream of heated vaporized fluid is supplied at relatively high pressure to the prime mover inlet and is expanded through the prime mover to a lower pressure discharge side where discharge fluid enters an accumulator. The discharge fluid is vaporized by passing it through an expansion device across a pressure differential to a lower pressure than the pressure at the prime mover discharge side. Latent heat of condensation in the discharge fluid being discharged from the prime mover is transferred by a heat exchanger to discharge fluid that has passed through the expansion device. Vaporized discharge fluid, to which heat has been transferred from fluid discharged from the prime mover, can be returned through a compressor and vapor drum to the prime mover inlet. Vaporized discharge fluid can be removed directly from the accumulator by a compressor where it is pressurized slightly above the pressure in the vapor drum, to which it is delivered directly, or it can be passed through a heat exchanger where the heat from the compressed fluid is transferred to an external media after leaving the compressor in route to the vapor drum. Liquid discharge fluid from the accumulator is pumped to a boiler liquid drum, then to the vapor drum through a heat exchanger. The liquid discharge fluid may be expanded through an orifice to extract heat from an external source at heat exchanger and discharged into the vapor drum or the accumulator, depending on its temperature upon leaving heat exchanger.
[0026] U.S. Pat. No. 7,096,665 to Stinger et al discloses a Cascading Closed Loop Cycle (CCLC) and Super Cascading Closed Loop Cycle (Super-CCLC) systems are described for recovering power in the form of mechanical or electrical energy from the waste heat of a steam turbine system. The waste heat from the boiler and steam condenser is recovered by vaporizing propane or other light hydrocarbon fluids in multiple indirect heat exchangers; expanding the vaporized propane in multiple cascading expansion turbines to generate useful power; and condensing to a liquid using a cooling system. The liquid propane is then pressurized with pumps and returned to the indirect heat exchangers to repeat the vaporization, expansion, liquefaction and pressurization cycle in a closed, hermetic process. The system can be utilized to generate power from low temperature heat sources.
[0027] Although numerous attempts have been made to capture waste heat from a primary heat source and reuse the energy in a secondary power system all of these attempts have fallen short. Thus, what is needed is an efficient, reliable and cost effect power system and heat engine that utilizes low temperature waste heat and is capable of operation using a low temperature and pressure working fluid.
SUMMARY OF THE INVENTION
[0028] Briefly described, the present invention includes an externally heated engine contained within an enclosure. A rotating member is mounted within the enclosure on bearings, with a shaft that extends through a seal, to the outside of the engine. Mounted upon the rotating member are one or more blades. A flow of gasses is directed upon the surface of these blades by the action of one or more stationary nozzles. As a result of the action of the gasses upon the blades, force is exerted upon the blades. This causes the rotating member to revolve, and torque is exerted upon the shaft while it rotates.
[0029] A rotating shaft is able to perform work, and this is accomplished by coupling the shaft to an electrical generating device thereby producing electrical power. Very large volumes of useful, moderate pressure gas are produced easily in this invention, at low temperatures, by using a working fluid such as a refrigerant. For instance, refrigerant R134 is one possible type of working fluid. Many other standard refrigerant types are also suitable. This refrigerant, in its liquid form, will boil very readily at low temperatures and pressures, and produce voluminous amounts of hot gas after being heated. R134 gas is particularly suited for this purpose, and completely avoids the need for high pressures and temperatures.
[0030] The blades mounted on the rotating member of the instant invention are not of traditional design. Prior art blades tend to be made for either high pressure and temperature gas flows—like in a jet engine for instance—or for flows of liquids, especially water, as in a hydroelectric plant for instance. These blades do not function well for low pressure and temperature gasses. The instant invention overcomes the limits of the prior art by combining a unique blade design with a particular design, to thereby extract power effectively under the desired conditions.
[0031] As configured, the nozzle directs the flow almost straight on to the surface of the blade. This creates a higher pressure on the upstream side of the blade than on the downstream side, and due to this impact effect, the pressure differential, delta P, produces a net force on the blade in the desired direction. Even a few pounds of delta P can produce a large torque if the blade surface area is great enough, and the diameter of the rotating member is large.
[0032] In addition, the blade design additionally takes advantage of the change of momentum in a flow that is produced by the geometry of the blade and the flow of the hot gaseous working fluid. By reversing the flow of working fluid the resulting reaction force on the blade will be large, and in the desired direction. The momentum of a flow of gas is proportional to the square of its velocity, and so the nozzles are designed to greatly accelerate the velocity of the flow, prior to reaching the blade.
[0033] The force generated by the velocity of the gas flow is a vector quantity, and so a change in direction can be as effective as a change in speed. So, rather than have the flow crash to rest up against the blade surface, the blade surface is curved, and in turn the flow is also turned almost 180 degrees. This produces a momentum change almost double that than if the flow had been brought to rest against the blade. The combination of very high (even supersonic) velocities and radical change in direction result in a very large change in momentum. Thus a large reaction force is exerted on the blade.
[0034] The combination of both types of action and the multiplying effects of the carefully directed gasses produce force levels not otherwise available with gasses at these pressures and temperatures.
[0035] Additionally, to extract even greater performance from the whole system energy is recovered on both the input and exhaust of the turbine loop of the power system. On the input side of the engine, heat is brought from the external source to the heat exchanger serving the turbine loop. This is done by circulating a heat transfer fluid from the heat source over to the heat exchanger. Obviously not all of the available heat in the stream of heat transfer fluid will be absorbed into the engine in a single pass through. If the fluid were discarded at that point, the heat not absorbed would be lost. The system employs a pump and a loop to recirculate the fluid back to the source, and thence back around to the engine. In this way the heat is not wasted, and is presented again and again to the engine and is ultimately nearly all used. Even the energy required to operate the pump is imparted to the flow, and thus captured and circulated around the process for eventual use.
[0036] On the exhaust side of the turbine loop, a similar process is employed. The heat not converted in the engine to electricity is gathered up in a heat exchanger, and passed over into a reclaiming loop. This reclaiming loop is essentially a heat pump, and is used to raise the temperature of the working fluid back up, and it is then presented to another heat exchanger. This heat exchanger in turn is used to inject the heat back into the primary loop of the engine, at an appropriate point. Even the energy used to run the compressor in the heat pump is captured in the working fluid, and is injected into the engine for use. The combination of recovery of heat, and reuse of heat, on both the input and the exhaust sides of the engine is extremely effective and makes far more power output available than would otherwise be the case, with a given heat source.
[0037] Alternatively, the loop that brings the external source of heat to the system can be directed to the reclaiming loop containing the heat pump system rather than to the turbine loop. The introduction of heat from the external heat source to the heat pump loop enables the utilization of waste heat in temperature ranges lower than the arrangement wherein the external heat source is in direct communication with the turbine loop. The utilization of relatively lower temperature waste heat greatly expands the areas of opportunity to recover waste heat that in practice is typically going unused.
[0038] Accordingly, it is an objective of the instant invention to operate a power system without a need for a dedicated source of combustion in order to operate.
[0039] It is a further objective of the instant invention to operate a power system on low temperature waste heat left over from power plant turbine condensers or air conditioning units.
[0040] It is a further objective of the instant invention to operate a power system on low temperature solar, or geothermal power.
[0041] It is yet another objective of the instant invention that is capable of efficiently utilizing low temperature heat sources and low pressure working fluids to generate substantial energy.
[0042] It is a still further objective of the invention to provide a highly efficient heat engine having one or more blades mounted on a rotating member that utilizes high velocity gas flow to apply force to the rotating member.
[0043] Other objects and advantages of this invention will become apparent from the following description taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE FIGURES
[0044] FIG. 1 is an exploded view of the core of the turbine showing the major components, including blades, nozzles, the rotating member, and the enclosure.
[0045] FIG. 2A is a front view of the rotating member with mounting recesses for the blades.
[0046] FIG. 2B is a side view of the rotating member with the mounting recesses for the blades.
[0047] FIG. 3A is a top view of one of the blades.
[0048] FIG. 3B is a side view of one of the blades
[0049] FIG. 4 shows one end plate, the rotating member, the blades and the nozzles superimposed so that their relationships can be seen.
[0050] FIG. 5A shows one end plate with the nozzles and also the mounting and locating holes for the plate.
[0051] FIG. 5B is a top view of the device shown in FIG. 5A .
[0052] FIG. 6A is a front view of the center portion, or ring, of the enclosure.
[0053] FIG. 6B is a top view of the center portion or ring shown in FIG. 6A
[0054] FIG. 7A is a front view of the opposite end plate with the exhaust ports.
[0055] FIG. 7B is a top view of the opposite end plate with the exhaust ports.
[0056] FIG. 8A shows a converging nozzle, aligned with a blade, and the resulting directions of flow.
[0057] FIG. 8B shows a converging nozzle aligned with a blade having an alternative shape to that shown in FIG. 8A .
[0058] FIG. 9 shows a converging-diverging nozzle, aligned with a blade, and the resulting directions of flow.
[0059] FIG. 10A is a cross sectional view of the converging nozzle.
[0060] FIG. 10B is a perspective view of the nozzle of FIG. 10A
[0061] FIG. 11A is a cross sectional view of the converging-diverging nozzle.
[0062] FIG. 11B is a perspective view of the nozzle of FIG. 11A .
[0063] FIG. 12 shows a full system diagram, with a buffering heat exchanger on the input loop, and using a generalized source of waste heat. This would facilitate having a heat pump on the input side, if needed.
[0064] FIG. 13 shows a full system diagram, with a buffering heat exchanger on the input loop, and using a solar array as a source of heat. This would facilitate having a heat pump on the input side, if needed.
[0065] FIG. 14 shows a full system diagram, without a buffering heat exchanger on the input loop, and using a generalized source of waste heat.
[0066] FIG. 15 shows a full system diagram, without a buffering heat exchanger on the input loop, and using a solar array as a source of heat.
[0067] FIG. 16 illustrates an alternative embodiment of the full system diagram shown in FIG. 12 wherein the external heat loop is in indirect heat exchange relationship with the heat pump loop.
[0068] FIG. 17 illustrates an alternative embodiment of the full system diagram shown in FIG. 13 wherein the external heat loop is in indirect heat exchange relationship with the heat pump loop.
[0069] FIG. 18 illustrates an alternative embodiment of the full system shown in FIG. 14 wherein the external heat loop is in indirect heat exchange relationship with the heat pump loop.
[0070] FIG. 19 illustrates an alternative embodiment of the full system shown in FIG. 15 wherein the external heat loop is in indirect heat exchange relationship with the heat pump loop.
[0071] FIG. 20 illustrates the full system similar to that shown in FIG. 16 but with an alternative form of sub-cooler in the turbine loop.
[0072] FIG. 21 illustrates the full system similar to that shown in FIG. 17 but with an alternative form of sub-cooler in the turbine loop.
[0073] FIG. 22 illustrates the full system similar to that shown in FIG. 18 but with an alternative form of sub-cooler in the turbine loop.
[0074] FIG. 23 illustrates the full system similar to that shown in FIG. 19 but with an alternative form of sub-cooler in the turbine loop.
[0075] FIG. 24 illustrates the full system similar to that shown in FIG. 20 but further including a hot gas bypass and shutoff valve, auxiliary expansion valves for start up, as well as an alternative form of electrical power generation.
[0076] FIG. 25 illustrates the full system similar to that shown in FIG. 21 but further including a hot gas bypass and shutoff valve, auxiliary expansion valves for start up, as well as an alternative form of electrical power generation.
[0077] FIG. 26 illustrates the full system similar to that shown in FIG. 22 but further including a hot gas bypass and shutoff valve, auxiliary expansion valves for start up, as well as an alternative form of electrical power generation.
[0078] FIG. 27 illustrates the full system similar to that shown in FIG. 23 but further including a hot gas bypass and shutoff valve, auxiliary expansion valves for start up, as well as an alternative form of electrical power generation.
DETAILED DESCRIPTION OF THE INVENTION
[0079] FIGS. 1 through 11 describe the heat engine. FIGS. 12 through 15 describe the complete thermodynamic system.
[0080] Beginning with the heat engine, FIG. 1 shows an exploded view of the heat engine components. As shown, the heat engine includes a left end bell 6 , a right end bell 7 , and a ring 4 that act together to enclose, seal, and support the engine. A rotating member 1 is mounted on a shaft 3 , and the shaft 3 is supported by bearings 5 that are mounted in both left end bell 6 and right end bell 7 . The shaft 3 is operatively connected to an electrical generator or other mechanical device to extract work from the rotating member 1 . The left end housing includes inlet ports 16 each supporting a nozzle 8 . The right hand bell 7 includes exhaust ports 17 . While the invention is illustrated with four inlet nozzles, the number of inlet ports and corresponding nozzles can vary from one to many. The left end bell 6 , the ring 4 and right end bell 7 are securely fastened together in a fluid tight relationship with a plurality of fasteners, such as bolts and nuts and seals (not shown). Bores 15 circumferentially spaced about the right and left end bells 6 and 7 and ring 4 are sized and configured to allow passage of each of the plurality of bolts,
[0081] Mounted on the rotating member 1 are blades 2 . It being understood that the numbers of blades and nozzles shown here are not the only quantities possible. For example these numbers could vary to increase the power output of the heat engine. Likewise, while bearings 5 are illustrated as ball bearings it should be understood that other types of bearings such as needle bearings, roller bearings, journal bearings, magnetic bearings and the like can be used as well. The rotating member 1 has a first planar surface 51 adjacent the left end bell 6 and a second planar surface 53 adjacent the right end bell 7 . An outer peripheral surface 55 is contiguous with both the first and second planar surfaces. The blade 2 has a width approximately equal to the distance between the first and second planar surfaces and a height that extends outward from the outer peripheral surface 55 .
[0082] FIGS. 2A , 2 B, 3 A and 3 B show some additional details of the rotating member and blade attachment. Rotating member 1 has dovetail shaped mounting slots 9 into which the blades 2 may be slid from the side. Blades 2 have a wedge shaped base 10 with mounting holes 13 through which pins and bolts are installed thereby holding the blades in place once they are slid into place in the mounting slots 9 . The combined effect is to prevent the blades from being slung away from the rotating member by the forces of rotation, and also to prevent the blades from moving side to side and thus rubbing on the side walls of the enclosure. Each blade 2 has a concave surface 12 on a first side surface of the blade and a convex surface 11 on a second side surface of the blade 2 .
[0083] In operation, the nozzles 8 direct high speed gasses at the concave surface 12 of each blade 2 . The angle of the nozzles and the shape of the blades provide numerous advantages. FIGS. 10A and 11A show the nozzles in cross section. Gas enters from the left, and is passed through a converging nozzle, as in FIG. 10A , or a converging-diverging nozzle, as in FIG. 11A to achieve a very high gas velocity. The nozzles are each fastened and sealed within their respective inlet ports 16 to facilitate removal and replacement as desired. In addition, differing nozzle designs may be used to operate the engine in differing circumstances requiring changes to flow properties. The nozzles are formed as a long slender hollow body which acts to receive the working gases and deliver them to a precise location and flowing in a desired direction. A tapered tip at the exit of the nozzle places the exiting flow into the desired position in the immediate proximity of the blades 2 that are mounted on the rotating member 1 .
[0084] The large total flow (mass) in combination with a very high gas flow velocity exiting these nozzles results in a very large momentum for the mass flow. This flow is significantly superior as a result, when compared to prior art engines.
[0085] FIGS. 8A , 8 B, and 9 illustrate this flow directed against the blades. FIG. 8A shows one embodiment the blade 2 and FIG. 8B shows an alternative embodiment for the blade As shown, the gas flow is introduced at a very shallow angle (10 degrees shown as an example) between the flow inlet and the blade 2 and 2 ′. The flow enters as nearly straight on to the concave surface 12 the blade 2 as is practical in this design. As a result of the high velocity gas flow across the blade two significant forces are imparted to the blade and the rotating member upon which the blade is mounted. As the flow impacts the blade directly, the pressure on the upstream side, or concave surface 12 , of the blade becomes greater than the pressure on the downstream or convex surface 11 of the blade. This creates a pressure differential (delta P) across the blade 2 . This delta P, multiplied by the surface area of the blade, produces a force, which in turn imparts a rotational force to the rotating member 1 . The second significant force is the result of the large momentum change. The flow enters nearly straight up, as shown in FIG. 8A , and exits nearly straight down, meaning that a nearly complete reversal (nearly 180 degrees) of the flow results. In the embodiment shown in FIG. 8B the flow enters the blade 2 ′ nearly straight up and exits not quite straight down creating a reversal of flow of approximately 120 degrees. As shown in FIG. 8B the blade 2 ′ has a downstream edge that directs the exhaust gas flow at a larger angle than blade 2 shown in FIG. 8A The configuration of the downstream edge of blade 2 ′ will prevent a build up of excess backpressure in the turbine.
[0086] Since velocity, and thus momentum, are vector quantities, a momentum of “M” entering, becomes a momentum of almost “−M” coming out. This creates a momentum change of M−(−M)=2M overall. The precise value of course depends on the exact blade angle. This is a great improvement over the momentum change that would have resulted from merely bringing the flow to rest against the blade, or by passing it across a slightly curved blade, both being done in the prior art. The total force on each blade is the combined result of both of the above significant forces.
[0087] FIG. 4 is a perspective view of the left end bell 6 , the rotating member 1 , the blades 2 , and the nozzles 8 , all superimposed in a single view.
[0088] The invention specifically provides a plurality of blades, and a plurality of nozzles, as shown in FIGS. 1 and 4 thereby creating multiple pulses of force to be applied to the rotating element 1 in parallel. An even larger number of force pulses are produced as the rotating member completes a full revolution. Providing multiple pulses in parallel, increases the torque available at a given instant. Providing multiple pulses per revolution increases the power produced per revolution. It is understood that one of ordinary skill in the art could alter the numbers of blades and nozzles, and thus the power available from an engine. The numbers shown are for illustration and are not limiting.
[0089] FIG. 10A is a cross sectional view of a converging nozzle 8 A and FIG. 10B is a perspective view of the converging nozzle 8 A.
[0090] FIG. 11B is a cross sectional view of a converging-diverging nozzle 8 B and FIG. 11B is a perspective view of the converging-diverging nozzle 8 B.
[0091] It is understood that one of ordinary skill in the art could devise variations of these mounting features. The features shown illustrate the structures and are not limiting. It is also within the scope of this invention that a turbine having a larger diameter would produce more torque from the same pressure differential. Likewise a turbine having wider blades would result in increasing the reactive surface area thereby creating more force and torque than turbines having blades of smaller width. The heat exchangers utilized in the following systems can be of various types and numbers and it is contemplated that one skilled in the art would select the type and appropriate number of units to achieve the greatest operating efficiency.
[0092] We next examine the total thermodynamic system, as presented in FIGS. 12 through 15 . These figures present optional configurations that are possible. Other variations of the basic configuration could be envisioned by one skilled in the art, and these figures are not limiting.
[0093] As shown in FIG. 12 there are 3 thermodynamic loops which make up the system. These are; the outside loop which brings heat from the source, the inside loop which runs the engine directly, and the heat pump loop, which recycles waste heat from the engine back into the system. We describe these in detail below.
[0094] The outside, or heat source loop, begins with heat source 18 . This source may be any source of low temperature heat, including waste heat from any number of waste heat sources or solar and geothermal heat sources as well. In this embodiment, the external heat source may supply temperatures as low as 250° F. In the operational mode of this loop, heat from the source 18 is conveyed by a first heat transfer fluid around to pump 21 . The first heat transfer fluid may be Paratherm NF®, or one of many commercial equivalents. The speed of pump 21 is controlled by control unit 22 , to achieve desired pressures and flow rates. A relief valve may be incorporated into the loop to avoid the buildup of damaging excess pressure. The hot heat transfer fluid is then conveyed to heat storage tank 23 , where it is held using a phase change material. This material in storage tank 23 changes phase from solid to liquid when heated to the desired temperature. The heat of fusion of such material being very large and capable of holding very large quantities of heat in a small volume. The stored heat may be used at a later time when the external heat source may become temporarily unavailable. Nitrogen tank 20 is used to hold an inert gas such as nitrogen in the tops of the expansion tanks to prevent suction pressures from falling too low and causing pump cavitations, and to prevent corrosion.
[0095] Once the desired amount of heat is stored, and the desired temperatures are reached, then secondary pump 25 is started. This pump circulates a second heat transfer fluid from the storage tank 23 over to the main heat exchanger 24 . Secondary speed controller 26 controls pump 25 and maintains the desired pressures and flow rates. Heat which has thus been supplied to the main heat exchanger 24 is now available for use. Also provided are bypass valves 47 which permit bypassing the heat source around the main heat exchanger 24 when desired, and also permit bypassing the heat into dump load 19 , under conditions where excess heat is present and must be discarded to the environment.
[0096] The inside, or turbine loop, functions in the following manner.
[0097] Heat from main heat exchanger 24 is conveyed by the inside, or turbine loop, heat transfer fluid, which is a refrigerant, to the heat engine 27 . Heat engine 27 is constructed and operated in the manner disclosed in FIGS. 1 through 11 . The refrigerant will operate at low temperatures of less than 300 deg F., and at pressures of less than 200 psig. In operation the heat transfer fluid within the turbine loop will condense at temperatures as low as 80 degrees F. and will boil at about 70 degrees F. when used in this heat engine. This heat engine 27 then operates, and conveys power to generator unit 28 . The generator unit 28 produces electricity which is conducted to an inverter 29 . The inverter 29 processes the power and makes it available for use externally. During warm-up, the refrigerant leaving heat exchanger 24 is bypassed around the heat engine through orifice 44 . This allows the inside loop to warm up, without presenting hot has to a cold heat engine, which would condense and cause problems. A very small amount of hot gas is passed through the heat engine during this time, to bring it up to temperature without excessive condensing of gas to liquid.
[0098] After leaving the engine 27 , the gaseous refrigerant passes into the heat exchanger 30 , which serves to condense the gas back to a liquid. In the process, heat is released to the heat pump loop, to be discussed presently. On leaving heat exchanger 30 , the inside loop refrigerant, now a liquid, passes through pressure control valve 46 , which prevents the pressure from dropping too low which would destabilize the loop function. Pressure control valve 46 is only needed in those cases where the system might be mounted in a cool climate. In such a case, the pressure of the condensed liquid coming out of the condensers could drop too low. Without enough pressure present, the refrigerant will not circulate in sufficient quantities, as pressure is needed to force circulation. The head pressure control valve prevents this loss of pressure by reducing temporarily and automatically, the capacity of the condensers, keeping the pressure high. The refrigerant is then stored in the receiver 45 , where it awaits further demand for circulation. Once further fluid is required, it departs the receiver 45 and makes its way through sub-cooler 38 , where it is cooled just sufficiently to prevent premature formation of any gas bubbles in the liquid. The flow then continues on to pump 41 . In addition to circulating the liquid around the loop, the pump acts to raise the pressure of the liquid to the level required for operation. Flow gauge 42 provides a measure of the rate of flow, which is controlled by the speed of the pump.
[0099] The high pressure liquid then proceeds to valve 40 . This valve is normally on, but is closed when the engine is off, to prevent flooding of the downstream components.
[0100] On passing through valve 40 the flow reaches heat exchanger 39 . Here it picks up reclaimed heat from the heat pump loop to be discussed presently. This raises the temperature of the liquid and causes it to boil and to form a gas. From here, the flow travels back to heat exchanger 24 , where it receives the balance of the required heat, and the cycle begins again. The system actually reclaims so much heat that the majority of the heat required to operate the engine comes from heat exchanger 39 . Only a small amount of heat is added on each pass around the loop from exchanger 24 . This is central to the efficiency of the total system, and is totally unlike prior art engines.
[0101] We next describe the heat pump, or heat reclaiming, loop.
[0102] Starting from receiver 36 , liquid heat reclaiming transfer fluid, again a refrigerant, is supplied under pressure to expansion valve 31 . Here the pressure is dropped sharply, in a controlled manner, and provided to heat exchanger 30 . In this process, the refrigerant begins to boil, and becomes a very cold gas. This cold gas extracts heat from the inside loop, through heat exchanger 30 , and carries away this heat to be reclaimed. The cold gas now travels to pressure control valve 32 , where the drop in pressure is regulated. Pressure control valve 32 is considered to be optional and is intended to prevent the evaporators in the system from becoming too cold. In practice this seldom happens. The gas pressure is kept high enough that the gas temperature does not drop to a temperature lower than that which is desired. From there, the gas travels to accumulator 34 where any liquid drops inadvertently remaining are held temporarily, thus preventing them from reaching and damaging the compressor.
[0103] The flow, still a cold gas, then travels to compressor 35 . While various types of compressors can be utilized it should be recognized that one skilled in the art would select the type and appropriate number of units to achieve the greatest operating efficiency. For example a multi unit scroll type compressor could be used. Here the gas is greatly compressed, reaching much higher levels of pressure and temperature. The flow then travels to heat exchanger 39 , where the temperature is now high enough so that the heat may be efficiently reinjected into the inside, or turbine loop process. Thus the heat has been reclaimed, along with the heat resulting from the compression work done by the compressor.
[0104] In the process of passing through heat exchanger 39 , the heat pump loop refrigerant gas cools sufficiently that it recondenses to a liquid once again. It then passes through sub-cooler 37 which condenses any remaining liquid and slightly sub-cools the liquid. It then passes through pressure control valve 33 which prevents the pressure from dropping too low and destabilizing the loop function, and then finally returns to receiver 36 , where the heat pump loop process begins again. A filter/dryer element is utilized to remove stray particles and also stray moisture from the loop thereby preventing all components from icing, damage and corrosion.
[0105] Additionally, system controller and display 43 is provided. This provides automatic control of the entire system, using software created for this purpose. It will be appreciated that a system of this complexity can only be operated in the field under automatic control.
[0106] FIG. 13 is a diagrammatic representation of the power system shown in FIG. 12 with a buffering heat exchanger on the input loop, substituting a solar array as a source of heat. This would facilitate having a heat pump on the input side, if needed.
[0107] FIG. 14 is a diagrammatic representation of the power system described in FIG. 12 however in this instance without a buffering heat exchanger on the input loop, and using a generalized source of waste heat.
[0108] FIG. 15 is a system similar to that shown in FIG. 14 without a buffering heat exchanger on the input loop, and substituting a solar array as a source of heat.
[0109] As shown in FIG. 16 through 19 there are 3 thermodynamic loops which make up an alternative embodiment of the power system. These are; the outside loop which brings heat from the source, the inside loop which runs the engine directly, and the heat pump loop, which recycles waste heat from the engine back into the system. In this embodiment the heat from the outside loop is directed to the heat pump loop rather than the turbine loop as in the previous embodiment thereby making it possible to use waste of lesser temperature than that used in the previous embodiment. Theoretically it is possible to use waste heat having a temperature as low as approximately 50 degrees F. however the volume of flow input heat would be very large in order to capture enough BTU's/hour, which might make the apparatus impractically large. It has been found the waste heat generated from conventional air conditioning units which produce waste heat of approximately 150 degrees F. are particularly well suited for this system. Likewise, waste heat from power plant turbine condensers which produce waste heat in the 120 degree F. range would also be particularly well suited for this system.
[0110] The system shown in FIGS. 16 through 19 shares most of the same components of the system as shown and described in the system illustrated in FIGS. 12 through 15 .
[0111] The outside, or heat source loop, begins with heat source 18 . This source may be any source of low temperature heat, including waste heat from any number of waste heat sources such as air conditioning units or power plant turbine condensers. The external heat source may supply temperatures as low as 50° F., but would preferably supply temperatures within the range of 120 to 150 degrees F. In the operational mode of this loop, heat from the source 18 is conveyed by a first heat transfer fluid around to pump 21 . The first heat transfer fluid may be Paratherm NF®, or one of many commercial equivalents. The speed of pump 21 is controlled by control unit 22 , to achieve desired pressures and flow rates. A relief valve may be incorporated into the loop to avoid the buildup of damaging excess pressure. The hot heat transfer fluid is then conveyed to heat storage tank 23 , where it is held using a phase change material. This material in storage tank 23 changes phase from solid to liquid when heated to the desired temperature. The heat of fusion of such material is very large and capable of holding very large quantities of heat in a small volume. The stored heat may be used at a later time when the external heat source may become temporarily unavailable. Nitrogen tank 20 is used to hold an inert gas such as nitrogen in the tops of the expansion tanks to prevent suction pressures from falling too low and causing pump cavitations, and to prevent corrosion.
[0112] Once the desired amount of heat is stored, and the desired temperatures are reached, then secondary pump 25 is started. This pump circulates a second heat transfer fluid from the storage tank 23 over to the main heat exchanger 24 . Secondary speed controller 26 controls pump 25 and maintains the desired pressures and flow rates. Heat which has thus been supplied to the main heat exchanger 24 is now available for use. Also provided are bypass valves 47 which permit bypassing the heat source around the main heat exchanger 24 when desired, and also permit bypassing the heat into dump load 19 , under conditions where excess heat is present and must be discarded to the environment.
[0113] The inside, or turbine loop, functions in the following manner.
[0114] Heat engine 27 is constructed and operated in the manner disclosed in FIGS. 1 through 11 . The refrigerant will operate at low temperatures of less than 300 deg F., and at pressures of less than 200 psig. In operation the heat transfer fluid within the turbine loop will condense at temperatures as low as 80 degrees F. and will boil at about 70 degrees F. when used in this heat engine. This heat engine 27 then operates, and conveys power to generator unit 28 . The generator unit 28 produces electricity which is conducted to an inverter 29 . The inverter 29 processes the power and makes it available for use externally. During warm-up, the refrigerant leaving heat exchanger 24 is bypassed around the heat engine through orifice 44 . This allows the inside loop to warm up, without presenting hot gas to a cold heat engine, which would condense and cause problems.
[0115] After leaving the engine 27 , the gaseous refrigerant passes into the heat exchanger 30 , which serves to condense the gas back to a liquid. In the process, heat is released to the heat pump loop, to be discussed presently. On leaving heat exchanger 30 , the inside loop refrigerant, now a liquid, passes through pressure control valve 46 , which prevents the pressure from dropping too low which would destabilize the loop function. Pressure control valve 46 is only needed in those cases where the system might be mounted in a cool climate. In such a case, the pressure of the condensed liquid coming out of the condensers could drop too low. Without enough pressure present, the refrigerant will not circulate in sufficient quantities, as pressure is needed to force circulation. The head pressure control valve prevents this loss of pressure by reducing temporarily and automatically, the capacity of the condensers, keeping the pressure high. The refrigerant is then stored in the receiver 45 , where it awaits further demand for circulation. Once further fluid is required, it departs the receiver 45 and makes its way through sub-cooler 38 , where it is cooled just sufficiently to prevent premature formation of any gas bubbles in the liquid. The flow then continues on to pump 41 . In addition to circulating the liquid around the loop, the pump acts to raise up the pressure of the liquid to the level required for operation. Flow gauge 42 provides a measure of the rate of flow, which is controlled by the speed of the pump.
[0116] The high pressure liquid then proceeds to valve 40 . This valve is normally on, but is closed when the engine is off, to prevent flooding of the downstream components.
[0117] On passing through valve 40 the flow reaches heat exchanger 39 . Here it picks up reclaimed heat from the heat pump loop and the outside or external heat loop, as will be discussed. This raises the temperature of the liquid and causes it to boil and to form a gas. From here, the flow travels to the heat engine 27 . Located immediately downstream of the heat engine 27 is a de-superheater 54 . The function of de-superheater 54 is to dispose of excess heat present in the turbine exhaust. Inside the turbine, enthalpy is converted to mechanical work. However, not all of the enthalpy can be effectively converted to work within the turbine and therefore a considerable amount of enthalpy will be left in the exhaust. If all of the enthalpy was transferred to the heat pump loop for recycling it would overwhelm the capacity of the heat pump. If the heat pump were made powerful enough to avoid being overwhelmed, the heat pump itself would then consume more energy than can be produced. The de-superheater 54 will dump this excess enthalpy to the environment using an air cooled heat exchanger. The de-superheater 54 does not condense the hot gas into a liquid but merely removes some excess energy from the hot gas. The system actually reclaims much of the heat and this is central to the efficiency of the total system, and is totally unlike prior art engines.
[0118] We next describe the heat pump, or heat reclaiming, loop.
[0119] Starting from receiver 36 , liquid heat reclaiming transfer fluid, again a refrigerant, is supplied under pressure to expansion valve 31 . Here the pressure is dropped sharply, in a controlled manner, and provided to heat exchanger 30 . In this process, the refrigerant begins to boil, and becomes a very cold gas. This cold gas extracts heat from the inside loop, through heat exchanger 30 , and carries away this heat to be reclaimed. The cold gas now travels to pressure control valve 32 , where the drop in pressure is regulated. Pressure control valve 32 and other valves designated as EPR valve are considered to be optional and are intended to prevent the evaporators in the system from becoming too cold. In practice this seldom happens. At this point the heat reclaiming fluid that has passed through heat exchanger 24 and is conveyed through line 50 into the flow. The heat from the external loop is added to the heat pump loop at this point. The gas pressure is kept high enough that the gas temperature does not drop to a temperature lower than that which is desired. From there, the gas travels to accumulator 34 where any liquid drops inadvertently remaining are held temporarily, thus preventing them from reaching and damaging the compressor.
[0120] The flow then travels to compressor 35 . Here the gas is greatly compressed, reaching much higher levels of pressure and temperature. The flow then travels to heat exchanger 39 , where the temperature is now high enough so that the heat may be efficiently reinjected into the inside, or turbine loop process. Thus the heat reclaiming loop contains the heat from the turbine loop that has been reclaimed, the heat from the external loop along with the heat resulting from the compression work done by the compressor.
[0121] In the process of passing through heat exchanger 39 , the heat pump loop refrigerant gas cools sufficiently that it recondenses to a liquid once again. Preferably, located immediately downstream of the heat exchanger 39 is a water cooled condenser 56 that is used only during the start-up and adjustment phases of the operation of the system. The water cooled condenser 56 provides a condensing function for the hot gas in the heat pump loop during such times (e.g. start up) when the main condenser has not yet ramped up to its intended capacity. If the water cooled condenser 56 were not present, hot gas could fail to fully condense, resulting in a breakdown of the heat pump loop function. Under certain parameters it is possible that water cooled condenser 56 may be considered to be optional. The heat pump refrigerant is then passed through sub-cooler 37 which condenses any remaining liquid and slightly sub-cools the liquid. It then passes through pressure control valve 33 which prevents the pressure from dropping too low and destabilizing the loop function, and then finally returns to receiver 36 , where the heat pump loop process begins again. A return line 52 connected upstream of expansion valve 31 will convey a portion of the refrigerant to heat exchanger 24 . A filter/dryer element is utilized to remove stray particles and also stray moisture from the loop thereby preventing all components from icing, damage and corrosion.
[0122] Additionally, system controller and display 43 is provided. This provides automatic control of the entire system, using software created for this purpose. It will be appreciated that a system of this complexity can only be operated in the field under automatic control.
[0123] FIG. 17 is a diagrammatic representation of the power system shown in FIG. 16 with a buffering heat exchanger on the input loop, substituting a solar array as a source of heat. This would facilitate having a heat pump on the input side, if needed.
[0124] FIG. 18 is a diagrammatic representation of the power system described in FIG. 16 however in this instance without a buffering heat exchanger on the input loop, and using a generalized source of waste heat.
[0125] FIG. 19 is a system similar to that shown in FIG. 18 without a buffering heat exchanger on the input loop, and substituting a solar array as a source of heat.
[0126] FIGS. 20 through 23 illustrate alternative system embodiment to those shown in FIGS. 16 through 19 . In this system embodiment a refrigerated sub-cooler 58 has been substituted to air cooled sub-cooler 38 in the previous embodiment. Refrigerated sub-cooler 58 is located immediately before pump 41 in the turbine. The refrigerated sub-cooler is capable of proper performance at any given ambient temperature. With the air cooled sub-cooler 38 , when the air temperature reaches a certain value (in the area of approximately 80 degrees F.) the sub-cooler malfunctions and causes the liquid refrigerant to flash into gas. Once the gas reaches the input of the pump the pump would not function properly and the turbine would stop working. In those cases where the ambient temperature is too warm the alternative sub-cooler design that uses refrigeration is required. A small amount of the heat pump capacity is tapped off through capillary tubes and sent to a heat exchange equipped to use it, as shown in FIGS. 20 through 23 . This refrigeration effect will reduce the liquid temperature flowing to the turbine pump 41 to a temperature several degrees below ambient. It will be cold enough that it cannot flash to a gas. This will eliminate the pump malfunction and consequent stopping of the turbine. Also, shown in the system embodiment of FIGS. 20-23 is an optional hot gas by pass valve 60 . By pass valve 60 acts to increase the flow of refrigerant during periods of low flow. This may occur at start up when the heat load is low. The hot gas injected increases the volume and velocity of the flow through the system, preventing unwanted buildup of refrigerant oil through the heat pump loop.
[0127] The system embodiment shown in FIGS. 24 through 27 illustrate an alternative embodiment to the system shown in FIGS. 20 through 23 . In this embodiment a start-up expansion valve 62 is employed in addition to the main expansion valve 31 . The main expansion valve 31 is a very large capacity unit designed to handle the full load imposed on the heat pump loop of the engine. This valve is self controlling; adjusting its output as required over a range of from 20% of the nameplate value up to a maximum of perhaps 120% of the nameplate value. Unfortunately, when the unit is first started, and is warming up, the load imposed is considerably less than 20% of the nameplate value. Hence the main expansion valve cannot be used, as it is impossible for it to throttle down far enough. The result is over-feeding of refrigerant, which overloads and overfills the heat exchanger to which it is connected. This problem is solved by having the control system switch between two valves. The main valve 31 is turned off during warm-up and a much smaller starter expansion valve 62 is turned on in its place. This starter expansion valve 62 has no problem throttling down far enough. Later, when the pressure and temperature sensors detect that the starter valve 62 has reached its full capacity, the starter valve 62 is switched off, and the system reverts to using the main expansion valve 31 instead. This embodiment discloses a generator 64 which can be any configuration that is capable of converting mechanical work into electrical energy. It should be recognized that this type of generator can be used in any of the aforementioned power system embodiments. One possible configuration would be the use of a three phase motor as a generator. It is self regulating, producing electrical power in exact proportion to the horsepower applied. This eliminates the need for costly power conversion and regulating components entirely. The three phase motor must be properly sized such that the maximum available shaft horsepower does not overload the motor electrically. Likewise, the mechanical output of heat engine 27 can be used as a power take off for any type of mechanical equipment that uses shaft horse power, such as but not limited to pumps, compressors, milling equipment, etc.
[0128] It will be appreciated that all of these components, including pressure gauges and service ports and other items not specifically discussed could be arranged in slightly different orders, and still lie within the intent of the system. The diagram presented is illustrative and not limiting.
[0129] All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
[0130] It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein.
[0131] One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.
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A power generation system that includes a heat source loop, a heat engine loop, and a heat reclaiming loop. The heat can be waste heat from a steam turbine, industrial process or refrigeration or air-conditioning system, solar heat collectors or geothermal sources. The heat source loop may also include a heat storage medium to allow continuous operation even when the source of heat is intermittent. Heat from the heat source loop is introduced into the heat reclaiming loop or turbine loop. In the turbine loop a working fluid is boiled, injected into the turbine, recovered condensed and recycled. The power generation system further includes a heat reclaiming loop having a fluid that extracts heat from the turbine loop. The fluid of the heat reclaiming loop is then raised to a higher temperature and then placed in heat exchange relationship with the working fluid of the turbine loop. The power generating system is capable of using low temperature waste heat is approximately of 150 degrees F. or less. The turbine includes one or more blades mounted on a rotating member. The turbine also includes one or more nozzles capable of introducing the gaseous working fluid, at a very shallow angle on to the surface of the blade or blades at a very high velocity. The pressure differential between the upstream and downstream surfaces of the blade as well as the change in direction of the high velocity hot gas flow create a combined force to impart rotation to the rotary member.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to an ironing pad assembly, and more particularly to an ironing pad that may be made portable, and which is adapted to be used on top of a table or similar flat-topped furniture for ironing.
[0002] Recently, domestic ironing has been reduced as a household chore from as much as two full days per week to as little as a few hours per week. Thus, the less frequent use of conventional ironing boards, requiring setting up, folding of legs, and storage, has become a nuisance in view of the sporadic times in which ironing is done today. In this regard, there have been several attempts to provide portable pads to alleviate the nuisance of legged ironing boards, as well as providing means for assisting in portability by rolling the pad into a spiral for insertion into a pouch-like cover. These efforts were deficient in desired lateral support, which had, for the most part, been of flat wooden boards. The prior art also taught several efforts to provide portability to ironing pads with folding means to reduce size. By way of example, such means were disclosed in U.S. Pat. Nos. 2,326,062 and 5,161,319, respectively granted to Beatrice Parker and to Mary Boyd. Both patents suggested the use of conventional wooden boards (See symbolic cross hatching used in the presentation of FIG. 7 of Parker and see the Abstract of the Boyd patent discussing a “plywood ironing board” with additional “wood supports”), fastened to conventional hardware store hinges 12 in Parker and hinges 20 a and 20 b in Boyd. Obviously, those structures are relatively heavy and cumbersome to carry and to set up for accomplishing the ironing task.
SUMMARY OF THE INVENTION
[0003] The present invention provides an improved ironing pad of multi-layered construction having at least one layer comprising an integrally formed hollow core construction having a plurality of substantially contiguous, open-cell cavities sandwiched between oppositely disposed, parallel panels. Preferably, the cavities are configured to included sidewalls extending between and substantially perpendicular relative to the oppositely disposed panels. It will be apparent that such construction materially lessens the weight of conventional ironing boards formerly utilizing solid wood construction. The compressive strength of open-cell, hollow core construction has been found to be substantially equivalent to solid construction.
[0004] Further, it is an additional object of this invention to provide a portable, multi-layered ironing pad assembly, which may include the aforementioned supporting layer of hollow core construction, or for that matter, a supporting layer of one or more longitudinally spaced, relatively thin, solid board or plywood construction. Such ironing pad assembly includes a longitudinally foldable sheet which, when folded, defines a close-sided envelope capable of being proportionally divided by transverse sewing stitches to provide adjacent pockets for receiving individual longitudinally adjacent, integrally formed, single panel units or supporting layers of open-core construction. The stitching together of overlying layers of the envelope layer also provides a satisfactory and convenient hinging means for folding the adjacent board or panels together. The folded sections also permit considerable reduction in pad length for convenience in transporting and storage.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a perspective view of an ironing pad in accordance with the invention, and being shown in unfolded position, ready to being placed on a table or other supporting flat surface.
[0006] FIG. 2 is a perspective view of a selected area broken way from the peripheral facing marginal edge of the pad of FIG. 1 and showing, in detail, a preferred arrangement of supporting hollow core construction used in forming a supporting layer of the pad.
[0007] FIG. 3 is a longitudinal side view of the ironing pad of FIG. 1 , and with its zippered closure member being shown in closed position.
[0008] FIG. 4 is an enlarged, fragmental, longitudinal side view of an end pocket portion of the ironing pad of this invention, and defined by an elliptically outlined area A
[0009] FIG. 5 is a longitudinal side view, similar to the view of FIG. 3 , but with oppositely disposed pocket portions being shown in folded upwardly and inwardly to reduce the length of the pad and enhance its portability.
[0010] FIG. 6A-6D , inclusive, are fragmented sectional views of individual, integrally formed, panel units which may be used individually or as a part of a hollow core supporting layer, and of selected size to reside in selected pockets of the preferred embodiment of the ironing pad described herein.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0011] Referring to the drawings, wherein like reference numerals indicate like or corresponding parts, and referring particularly to FIG. 1 , there is shown an ironing pad assembly 10 which may be of portable construction, and which may be supported by a table or similar furniture having a flat supporting surface. It will be obvious that pads of this type should be capable of being folded, or otherwise capable of being of reduced in length and to be of lightweight construction.
[0012] The ironing pad assembly 10 made in accordance with the present invention, is preferably multi-layered, and includes a cover layer 12 of conventional heat-resistant fabric material that extends around the top of the pad assembly 10 , the side 14 and the under layer 16 . The various layers of the laminated pad assembly 10 may be conveniently enclosed by means of an elongated zipper unit 18 . The zipper unit 18 need only extend around the periphery of the pad assembly 10 to provide access to the open-ended, hinged, pocket portions to be hereinafter described. The upper and lower marginal edges of the pad assembly 10 are preferably joined, sewn together, and covered by a sewn-on welting fabric strip 20 . The pad assembly 10 is preferably constructed to be folded along the dotted lines 22 .
[0013] With particular reference to FIG. 2 , it will be noted that a lightweight, supporting layer 30 is preferably provided, especially when the pad assembly 10 is of the portable type. The layer 30 is preferably comprised of laterally adjacent integrally formed, individual supporting open-cell units, details of which are shown in the views of FIGS. 2-5 , inclusive, and respectively designated 30 a , 30 b and 30 c . The individual hollow core units 30 a , 30 b and 30 c are integrally formed of lightweight, pressed paperboard having a series of open-cells 31 (see FIG. 2 ) including upstanding side walls 33 . The sidewalls 33 are substantially perpendicular to and extend between parallel, oppositely disposed, relatively flat, upper and lower panel units 36 and 38 . This construction was found to be comparatively lightweight and relatively strong for its size. A very simple compression strength test indicated that a young man of approximately 225 pounds, and wearing flat-healed shoes, was able to stand on a sample piece of ½ inch paper pressboard, as described herein, without any damage to the surface to the panel, even when the panel was covered with a layer of relatively thin, heat reflective, aluminum foil 37 (approximately 2 mils.). As disclosed in the enlarged detail view of FIGS. 3 and 4 , integrally formed, adjacent supporting hollow core units 30 a and 30 c , respectively reside in end pocket portions 34 a and 34 c and an elongated intermediate pocket 34 b disposed adjacent to and between end pockets 34 a and 34 c . The elongated, intermediate hollow core unit 32 b completes the lateral support for ironing pressure exerted on the cover layer 12 of the pad assembly 10 . The releasable zipper unit 18 provides access for entry of the respective hollow core units 32 a , 32 b and 32 c in their respective pocket portions 34 a , 34 b and 34 c . The adjacent pockets 34 a - 34 b and 34 b - 34 c are formed by transverse stitching 36 (See FIG. 4 ). The transverse stitching 36 provides the additional function of becoming a hinge for supporting and folding of adjacent units 30 a - 30 b and 30 b - 30 c . The stitching 36 sewn at fold lines 22 (See FIG. 1 ), conveniently provides the means for folding the pad assembly 10 lengthwise to reduce its overall length, and also to eliminate need for heavy, cumbersome, hardware hinges screwed into relative heavy, cumbersome, wood or plywood support members of prior art devices.
[0014] A preferred construction of individual hollow core units 30 a , 30 b and 30 c , as shown in the views of FIGS. 2 and 4 , include adjacent, contiguous cavities, or cells 31 defined by adjoining side walls 33 . In this preferred construction, each of the sidewalls 33 extend between the upper panel unit 36 and the lower panel unit 38 . Each of the panel units 36 and 38 are relatively flat so that the subassembly of each of the units 30 a , 30 b and 30 c , along with substantially perpendicular sidewalls 33 , will provide a supporting layer of maximum cross-sectional strength. It is conceivable, however, where less strength is required, the open-cell units 30 a , 30 b and 30 c may be comprised of hollow core cavities with defining walls not of particular orientation (not shown herein). It will also be apparent that any cavity configuration must be of sufficient dimension to provide low heat conduction characteristics. Such low heat conduction is required to withstand the relatively high ironing temperatures of modern flat irons and steam irons.
[0015] The construction of the supporting layer 30 ( 30 a , 30 b and 30 c ) may be, when desired, reduced in height to include a single panel unit 36 . The individual panel units 36 and/or 38 may be selected from conventional panel board material. There are many available panel boards which provide adequate compressive strength, particularly for an ironing board pad such as the pad assembly described herein. Satisfactory individual supporting panel units 36 and/or 38 have been fabricated from conventional sheets having thicknesses ranging from 3/16 th inch to 1 inch.
[0016] FIG. 6A is illustrative of a conventional plywood substrate with a reflective surface 32 c.
[0017] FIG. 6B exemplifies a solid substrate known as “GatorBoard” or “FireFlex” with an exposed heat reflective surface 32 c . A synthetic wood substrate with a heat reflective top surface 32 c may also be selected from products known as “SynPly”, “Gatorply” or “Luxcell” as well as conventional panel board made of multiple corrugated cardboard substrate or composite material with a heat reflective top layer 32 c.
[0018] Some of these materials are flame resistant or may be treated to be flame resistant. All of them have high tensile and compressibility strength. Thicknesses may vary from 3/16 th inch to 1 inch thick. An example disclosed in FIGS. 6A, 6B and 6 C, these would be considered rigid solid-core materials, whereas example shown in FIG. 6C would be semi- or rigid-open cell (hollow-core) materials. There are, of course, many plastics available on the market that may be used but must be selected where a relatively high temperature caused by the hot iron may be of concern.
[0019] For purposes of obtaining the above-mentioned materials, “GatorBoard” is readily obtainable in thicknesses between 3/16 th inch and 1 inch from Art Grafix, a division of Stover Graphics of Beacon Falls, Conn., whereas “FireFlex” is a Melamine base obtainable from FireFlex Systems, Inc. of Boisbarand, Canada 37H 1N8. The three materials identified by the trademarks “SynPly”, “Gatorply” and “Luxcell” are each obtainable from Uniwood, Alcan Composites of Statesville, N.C. The multiple corrugated cardboard substrate or composite material is readily available by consulting local business telephone directories through an Internet browser or other local paper suppliers.
[0020] Depending upon the desired construction of the ultimate manufacturer, there may be another layer 44 added to cushion pressure exerted on the cover layer 12 during ironing. Also, consumer demand may require a bottom layer (not shown) of non-slip rubber mesh material, such as made from polyethylene mesh.
[0021] The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
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An ironing pad having a relatively flexible laminate structure including among its layers an integrally formed, independent layer supporting hollow core units which are disposed adjacent to one another and being received in an individual pocket formed in overlying layers of a closed-sided envelope, and in which hollow core is formed of a plurality of contiguous adjacent open-cell cavities which provide a heat barrier in addition to a layer of relatively high-compressive strength for supporting the weight of steam or flat iron pressing of fabric materials. The pad assembly may include three separate hollow core heat barrier units in hinged relationship with one another to provide a relatively shortened lengthwise dimension to the entire assembly when the end units are folded.
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TECHNICAL FIELD
The present invention relates generally to motor vehicle propeller shafts, and more particularly concerns a constant velocity joint having improved crash-worthiness and energy absorption capabilities within a propeller shaft of a motor vehicle.
BACKGROUND OF THE INVENTION
Constant velocity joints are common components in automotive vehicles. Typically, constant velocity joints are employed where transmission of a constant velocity rotary motion is desired or required. Common types of constant velocity joints include end motion or plunging and fixed motion designs. Of particular interest is the end motion or plunging type constant velocity joints, which include a tripod joint, a double offset joint, a cross groove joint, and a cross groove hybrid. Of these plunging type joints, the tripod type constant velocity joint uses rollers as torque transmitting members, and the others use balls as torque transmitting members. Typically, these types of joints are used on the inboard (toward the center of the vehicle) on front sideshafts and on the inboard or outboard side for sideshafts on the rear of the vehicle and on the propeller shafts found in rear-wheel drive, all-wheel drive, and four-wheel drive vehicles.
Propeller shafts are commonly used in motor vehicles to transfer torque and rotational movement from the front of the vehicle to a rear axle differential such as in a rear wheel and all wheel drive vehicles. Propeller shafts are also used to transfer torque and rotational movement to the front axle differential in four-wheel drive vehicles. In particular, two-piece propeller shafts are commonly used when larger distances exist between the front drive unit and the rear axle of the vehicle. Similarly, sideshafts are commonly used in motor vehicles to transfer torque from a differential to the wheels. The propeller shaft and sideshafts are connected to their respective driving input and output components by a joint or series of joints. Joint types used to connect the propeller shaft and sideshafts interconnecting shafts include Cardan, Rzeppa, tripod and various ball type joints.
In addition to transferring torque and rotary motion, in many automotive vehicles the propeller shaft and axle drives allow for axial motion. Specifically, axial motion is designed into two-piece propeller shafts by using an end motion or plunging type constant velocity joint.
Besides transferring mechanical energy and accommodating axial movement, it is desirable for plunging constant velocity joints to have adequate crash-worthiness. In particular, it is desirable for the constant velocity joint to be shortened axially preventing the propeller shaft from buckling, penetrating the passenger compartment, or damaging other vehicle components in close proximity of the propeller shaft. In many crash situations, the vehicle body shortens and deforms by absorbing energy that reduces the acceleration; further protecting the occupants and the vehicle. As a result, it is desirable for the propeller shaft be able to reduce in length during the crash, allowing the constant velocity joint to travel beyond its operational length. It is also desirable for the constant velocity joint within the propeller shaft to absorb a considerable amount of the deformation energy during the crash. Reduction of the propeller shaft length during a crash situation is often achieved by having the propeller shaft telescopically collapse and energy absorb thereafter.
In telescopic propeller shaft assemblies, the joint must translate beyond the constant velocity joint limitation before the telescopic nature of the propeller shaft is effectuated. In some designs, the propeller shaft must transmit the torque as well as maintain the ability to telescope. In other designs, the telescopic nature of the joint only occurs after destruction of the joint, joint cage or some type of joint retaining ring. Still in other designs, the joint must first translate the balls out of and off the race area before the telescopic attribute can be had for axial joint displacement. The limitation of the telescopic ability is that the constant velocity joint must be compromised before axial displacement can occur in a crash situation. Therefore, there is a desire to have a constant velocity joint that can accommodate the axial displacement during a crash.
Furthermore, the energy absorption only occurs after the functional limit or end of the constant velocity joint has been surpassed. This causes a time delay in the energy absorption ability of the propeller shaft. Then and only then, the energy absorption is accomplished and typically has a force step or impulse energy absorption pattern. After the initial energy absorption, typically, there is no further energy absorption in the propeller shaft. In another situation there is further energy absorption, but only after the joint balls successfully translate off the joint race and onto the propeller shaft. Therefore, there is a desire to have a constant velocity joint that has a controlled or tuned force energy absorption profile over a range of the joint's axial travel distance, especially when the normal operational range of the joint has been surpassed.
It would be advantageous to have the above-mentioned features in the cross groove joint. The cross groove constant velocity joint is commonly know by automotive manufactures and suppliers as a VL type joint and the invention, here below, relates to this type of joint. A VL joint is used for accommodating rotary and axial displacements in a propeller shaft of a motor vehicle and for connecting a drive unit to a rear axle gearbox, having at least two articulatably connected shaft portions. The joint has an outer joint part with outer ball tracks, an inner joint part with inner ball tracks, a plurality of torque transmitting balls each guided in outer and inner ball tracks associated with one another. The associated outer ball tracks on the one hand and inner ball tracks on the other hand, forming angles of intersection in respect of the central axis of the joint, which are of identical size but are set in opposite directions. The balls are held in a constant velocity plane when the joint is axially displaced or articulated by a ball cage, which is provided with a plurality of cage windows each accommodating one of the balls. The outer joint part is connected to a hollow shaft and the inner joint part is connected to a connecting shaft allowing axial displacement.
SUMMARY OF THE INVENTION
The present invention is directed toward a constant velocity joint for use in a vehicle driveline having at least one energy absorption element for improved crash-worthiness and energy absorption. In particular, at least one energy absorption element of the constant velocity joint, described herein, is tuned to control joint energy absorption for axial displacement beyond the normal axial travel range of the joint.
The present invention provides an energy absorbing plunging constant velocity joint for improved crash-worthiness. In particular, a constant velocity joint has an outer joint part, an inner joint part, a plurality of torque transmitting balls, and a ball cage having cage windows for retaining the torque transmitting balls in the outer and the inner ball tracks of the outer and the inner joint parts. The torque transmitting balls are retained in a constant velocity plane by the ball cage and guided by corresponding pairs of the outer and the inner ball tracks. The outer and the inner ball tracks form angles of intersection with respect to an axis where the angles are identical in size but set in opposite directions to one another. The outer joint part and the inner joint part operate in a normal axial range when transmitting torque in a propeller shaft. There is an inner extended axial range and an outer extended axial range, which can accommodate axial motion when the inner joint part and the outer joint part are thrust beyond the normal axial range. There is at least one energy absorption surface located in the outer extended axial range or in the inner extended axial range. The energy absorption surface interferes with at least one of the torque transmitting balls when the joint is operated beyond said normal axial range, allowing the joint to absorb the thrust energy.
An advantage of the present invention is that the constant velocity joint absorbs energy within an extended axial range when the joint is thrust beyond its normal axial range. The present invention itself, together with further objects and intended advantages, will be best understood by reference to the following detailed description, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of this invention, reference should now be made to the embodiments illustrated in greater detail in the accompanying drawings and described below by way of examples of the invention.
In the drawings:
FIG. 1 shows a plan view of a four-wheel drive vehicle driveline in which the present invention may be used to advantage.
FIG. 2 shows a half-sectional view of a vehicle propeller shaft assembly comprising one or more constant velocity joints in accordance with one embodiment of the present invention.
FIG. 3 shows a half-sectional view of a constant velocity joint in accordance with one embodiment of the present invention in a propeller shaft assembly.
FIG. 4 shows a partial view of a constant velocity joint in accordance with alternative embodiments of the present invention.
FIGS. 5A and 5B show a partial view of a constant velocity joint in accordance with alternative embodiments of the present invention.
FIG. 6 shows a layout view of an outer ball track according to one embodiment of the present invention.
FIG. 7 shows a layout view of an inner ball track according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, various operating parameters and components are described for one constructed embodiment. These specific parameters and components are included as examples and are not meant to be limiting.
While the invention is described with respect to an apparatus having improved crash-worthiness within a propeller shaft of a vehicle, the following apparatus is capable of being adapted for various purposes including automotive vehicle drive axles or other vehicles and non-vehicle applications which require collapsible propeller shaft assemblies.
Referring now to FIG. 1 , there is shown a plan view of four-wheel drive vehicle driveline 10 wherein a constant velocity joint 11 in accordance with the present invention may be used to advantage. The driveline shown in FIG. 1 is typical for a four-wheel drive vehicle, however, it should be noted that the constant velocity joint 11 of the present invention can also be used in rear wheel drive only vehicles, front wheel drive only vehicles, all wheel drive vehicles, and four-wheel drive vehicles. The vehicle driveline 10 includes an engine 14 that is connected to a transmission 16 and a power takeoff unit such as a transfer case 18 . The front differential 20 has a right hand sideshaft 22 and left hand sideshaft 24 , each of which are connected to a wheel and deliver power to the wheels. On both ends of the right hand front sideshaft 22 and the left hand front sideshaft 24 are constant velocity joints 12 . A front propeller shaft 25 connects the front differential 20 to the transfer case 18 . A propeller shaft 26 connects the transfer case 18 to the rear differential 28 , wherein the rear differential 28 is coupled to a rear right hand sideshaft 30 and a rear left hand sideshaft 32 , each of which is connected to a respective wheel. constant velocity joints 12 are located on both ends of the sideshafts 30 , 32 that connect the rear wheels to the rear differential 28 . The propeller shaft 26 , shown in FIG. 1 , is a two-piece propeller shaft. Each end includes a rotary joint 34 which may comprise a cardan joint or any one of several types of constant velocity joints or non-constant velocity joints. Between the two pieces of the propeller shaft 26 is a high speed constant velocity joint 11 in accordance with the present invention as well as a support 36 such as an intermediate shaft bearing. The constant velocity joints 11 , 12 , 34 transmit power to the wheels through the propeller shaft 26 , front propeller shaft 25 and sideshafts 22 , 24 , 30 , 32 even if the wheels or the shafts 25 , 26 have changing angles due to the steering or raising or lowering of the suspension of the vehicle. The constant velocity joints 11 , 12 , 34 may be any of the standard types known and used to advantage, such as a plunging tripod, a cross-groove joint, a cross-groove hybrid joint, or a double offset joint or any other type of constant velocity joints.
FIG. 2 shows a half-sectional view of a vehicle propeller shaft 26 assembly comprising one or more constant velocity joints 11 , 34 in accordance with one embodiment of the present invention such as shown in FIG. 1 . The propeller shaft 26 assembly may include one, two or a combination of constant velocity joints 11 , 34 . The constant velocity joint can be of a monobloc, disc, flanged, or other styles of design known to those in the art. The propeller shaft 26 assembly transfers torque from the transmission 16 to the rear differential 28 by way of the propeller shaft 26 . The constant velocity joints 11 , 34 are axially plungeable. The constant velocity joints 11 , 34 have an inner joint part 38 and an outer joint part 40 . The outer joint part 40 of constant velocity joint 11 is connected to one end of a hollow shaft 42 by, for example, a friction weld. The hollow shaft 42 is defined by a cylindrical shell having an inner diameter that is smaller than its outer diameter and two open ends. The other end of the hollow shaft 42 is connected to a rotary joint 35 that is connectable to a rear differential 28 or a transmission 16 depending upon the directional orientation of propeller shaft 26 . Into the inner joint part 38 there is inserted a connecting shaft 44 which, at a certain distance from the joint 11 , is supported by a shaft bearing 36 .
Similarly, in combination or alternatively, the outer joint part 40 of constant velocity joint 34 is connected to one end of a hollow shaft 43 by, for example, a bolted connection. The other end of the hollow shaft 43 is connected to a shaft bearing 36 on the opposite side of connecting shaft 44 . Into the inner joint part 38 there is inserted a connecting shaft 45 which is connectable to a transmission 16 or a rear differential 28 depending upon the directional orientation of propeller shaft 26 . The propeller shaft 26 assembly transfers torque from the transmission 16 to the rear differential 28 by way of the propeller shaft 26 .
In addition to torque transfer, the propeller shaft 26 can accommodate axial and angular displacements within the constant velocity joints 11 , 34 , where axial movement and articulation of the hollow shafts 42 , 43 is relative to the connecting shafts 44 , 45 . Axial movement is relative to the shafts centerline. In certain crash situations, however, the connecting shafts 44 , 45 will move, and thrust axially toward the shafts 42 , 43 , beyond the joints normal operating range while engaging a tuned energy absorption surface. The tuned energy absorption surface extends over an extended axial range of the constant velocity joints 11 , 34 . Energy may be absorbed until the extended axial range is exceeded and the joint parts are released into the hollow shafts 42 , 43 or are impeded by the hollow shafts 42 , 43 . The required thrust for axial movement may be increased or decreased by increasing or decreasing the amount of interference caused by the energy absorption surface.
FIG. 3 shows a half-sectional view of a constant velocity joint 11 in accordance with one embodiment of the present invention in a propeller shaft assembly. The joint 11 is an axially plungeable constant velocity joint of the cross-groove type. For purposes of clarity, the cross-groove joints of FIGS. 3–7 are shown with exaggerated outer joint part ball track lengths such that the energy absorption features discussed herein can be more easily illustrated. The constant velocity joint 11 comprises an outer joint part 50 , an inner joint part 52 , a ball cage 54 and more than one torque transmitting balls 56 each held in a cage window 58 . The outer joint part 50 comprises a cylindrical open end 66 located proximate to the hollow shaft 42 , outer ball tracks 60 which longitudinally extend over the length of the outer joint part 50 , having a normal axial range N and an outer extended axial range E. The inner joint part 52 comprises inner ball tracks 61 which longitudinally extend over the length of the inner joint part 52 , having a normal axial range N and an inner extended axial range IE. The inner extended axial range IE of the inner joint part 52 is correspondingly positioned in opposite direction, about the normal axial range N, from the outer extended axial range E of the outer joint part 50 . Each inner ball track 61 is associated with a corresponding outer ball track 60 forming angles of intersection with respect to an axis. The angles are identical in size but set in opposite directions and corresponding to the inner ball tracks 61 and the outer ball tracks 60 . The length of each inner ball track 61 is commensurate with the length of each outer ball track 60 , although shown in the figure as having different lengths for clarity of the inventive aspects. Alternatively, it can be recognized that the inner ball tracks 61 and the outer ball tracks 60 can have varying lengths, the shorter of which correspondingly commensurate to the angles of intersection of the longer of the two. Thus, the outer joint part 50 and the inner joint part 52 are driveably connected through the torque transmitting balls 56 located in the ball tracks 60 , 61 ; there being one torque transmitting ball 56 for each corresponding pair of ball tracks 60 , 61 . The torque transmitting balls 56 are positioned and maintained in a constant velocity plane by the ball cage 54 , wherein the ball cage 54 is located between the two joint parts 50 , 52 . The constant velocity joint 11 permits axial movement since the ball cage 54 is not positionably engaged to the inner joint part 52 and the outer joint part 50 .
The outer joint part 50 is connected to a hollow shaft 42 that is fixed to the outer joint part by, for example, a friction weld. The hollow shaft 42 may also be flanged and connected to the outer joint part by way of, for example, bolts.
Into the inner joint part 52 there is inserted a connecting shaft 44 . A plate cap 46 is secured to the outer joint part 50 . A convoluted boot 47 seals the plate cap 46 relative to the connecting shaft 44 . The other end of the joint 11 at the cylindrical open end 66 , i.e., towards the hollow shaft 42 , is sealed by a grease cover 48 . In addition, the cover 48 may provide some energy absorption should the connecting shaft 44 be thrust beyond the extended axial range E of constant velocity joint 11 . The constant velocity joint 11 is designed to operate in it normal axial range N until, however, compression from a crash or an unintended thrust is applied forcing the inner joint part 52 , the ball cage 54 , and the torque transmitting balls 56 into or through the extended axial ranges E, IE of both joint components.
In this embodiment of the present invention, the joint has a tuned energy absorption surface 74 , which is a circlip 76 . The circlip 76 is circumferentially located in the outer extended axial range E and coupled to the outer joint part 50 . The circlip 76 , in this embodiment, is an annular ring, made from a deformable material, preferably metal or plastic, and positionable in the outer joint part 50 so as to reside in the outer ball tracks 60 . When the connecting shaft 44 along with the inner joint part 52 , the torque transmitting balls 56 and the ball cage 54 are thrust, as a result of an unintended force, such as a crash, beyond the normal axial range N and into the outer extended axial range E of the joint 11 , the torque transmitting balls 56 will interfere with or be impeded by the circlip 76 . The impediment of the circlip 76 causes an increase in the thrust required for axial motion allowing energy to be absorbed by the constant velocity joint 11 and the propeller shaft 26 . The circlip 76 can be tuned to achieve different force levels, allowing for design of a controlled energy absorption profile within the constant velocity joint 11 . The tuning may be accomplished by changing the size, the shape, the material, or the location of the circlip 76 . There may also be more than one circlip 76 located within the outer extended axial range E of the constant velocity joint 11 .
In addition or alternatively, the circlip 76 may be circumferentially located in the inner extended axial range IE and coupled to the inner joint part 52 (not shown in FIG. 3 ). When the connecting shaft 44 along with the inner joint part 52 , the torque transmitting balls 56 and the ball cage 54 are thrust, as a result of an unintended force, such as a crash, beyond the normal axial range N and into the inner extended axial range IE of the joint 11 , the torque transmitting balls 56 will interfere with or be impeded by the circlip 76 . The impediment of the circlip 76 causes an increase in the thrust required for axial motion allowing energy to be absorbed by the constant velocity joint 11 and the propeller shaft 26 .
Thus, under normal operating conditions, the torque transmitting balls 56 will operate in the normal axial range N of the constant velocity joint 11 . In certain crash situations, however, the connecting shaft 44 along with the inner part 52 , the ball cage 54 and the torque transmitting balls 56 will be thrust toward the hollow shaft 42 allowing track and bore energy to be absorb along the outer extended axial range E or the internal extended axial range IE caused by the impediment of the circlip 76 upon the outer joint part 50 or inner joint part 52 , respectfully. When the joint is positioned in the outer extended axial range E, it is correspondingly positioned in the inner extended axial range IE. It is contemplated that the circlip 76 could be a foreign body, having the same energy absorbing effect as the ring given in this embodiment, residing upon the outer extended axial range E or inner extended axial range IE absorbing plastic energy.
FIG. 4 shows a partial view of a constant velocity joint in accordance with alternative embodiments of the present invention. In this embodiment, there is a tuned energy absorption surface 80 , which is a bore surface 82 . The bore surface 82 is circumferentially located in the extended axial range E, has an inclination θ and is coupled to the inner bore 64 of the outer joint part 50 between any two outer ball tracks 60 . In addition to or in the alternative, the bore surface 82 can have multiple inclinations, stepped inclination, or variable inclination. The bore surface 82 may be located between any set of one or more outer ball tracks 60 or upon the entire inner bore surface 64 in the outer extend axial range E. The bore surface 82 may be manufactured by layering, i.e. welding, material upon the inner bore surface 64 of the outer joint part 50 or by undercutting, while machining, the inner bore surface 64 . One embodiment contemplates the bore surface 82 to be manufactured from the same material as the outer joint part 50 by reducing the inner bore 64 diameter and forming an inclination θ in the outer extended axial range E during the machining process. However, one in the trade would recognize that the bore surface 82 could be accomplished, among other ways, by tacking, staking, or riveting a material upon the inner bore 64 . Thus, when the connecting shaft 44 along with the inner joint part 52 , the torque transmitting balls 56 , and the ball cage 54 are thrust, as a result of an unintended force, such as a crash, beyond the normal axial range N and into the outer extended axial range E of the joint 11 , the ball cage 54 will interfere with or be impeded by the bore surfaces 82 . The impediment of the bore surfaces 82 causes an increase in the thrust required for axial motion allowing energy to be absorbed by the constant velocity joint 11 and the propeller shaft 26 . The bore surfaces 82 can be tuned to achieve different force levels, allowing for design of a controlled energy absorption profile within the constant velocity joint 11 . The tuning may be accomplished by changing the size, the shape, the material, or the location of the bore surfaces 82 .
In addition or alternatively, the energy absorption surface 80 may be an inner energy absorption surface 81 located in the inner extended axial range IE on the outer face 62 of the inner joint part 52 . When the connecting shaft 44 along with the inner joint part 52 , the torque transmitting balls 56 , and the ball cage 54 are thrust, as a result of an unintended force, such as a crash, beyond the normal axial range N and into the inner extended axial range IE of the joint 11 , the ball cage 54 will interfere with or be impeded by the inner energy absorption surfaces 81 . The impediment of the inner energy absorption surfaces 81 causes an increase in the thrust required for axial motion allowing energy to be absorbed by the constant velocity joint 11 and the propeller shaft 26 .
Thus, under normal operating conditions, the ball cage 54 will operate in the normal axial range N of the constant velocity joint 11 . In certain crash situations, however, the connecting shaft 44 along with the inner part 52 , the ball cage 54 and the torque transmitting balls 56 will be thrust toward the hollow shaft 42 allowing bore energy to be absorb along the outer extended axial range E and or the internal extended axial range IE caused by the impediment of the energy absorption surface 80 upon the outer joint part 50 or inner joint part 52 , respectfully.
Any number of inner energy absorption surfaces 81 or bore surfaces 82 may be combined with any number of circlips 76 , as in FIG. 3 , in the outer extended axial range E or the inner extended axial range IE of the constant velocity joint 11 to achieve a tuned and controlled energy absorption characteristic.
FIG. 5A shows a partial view of a constant velocity joint in accordance with an alternative embodiment of the present invention. In this embodiment, there is a tuned energy absorption surface 86 , which is a track surface 88 . The track surface 88 has a taper 90 and is longitudinally located in the outer extended axial range E of an outer ball track 60 of the outer joint part 50 . There can be one or more track surfaces 88 located on anyone of the other outer ball tracks 60 . The taper 90 may extend linearly over the outer extended axial range E as shown in the layout view of FIG. 6 . Alternatively, the track surface may have a variable taper or a stepped taper of increasing or decreasing size ( FIG. 5B ). Thus, when the connecting shaft 44 along with the inner joint part 52 , the torque transmitting balls 56 , and the ball cage 54 are thrust, as a result of an unintended force, such as a crash, beyond the normal axial range N and into the outer extended axial range E of the joint 11 , the torque transmitting balls 56 will interfere with or be impeded by the track surface 88 . The impediment of the track surface 88 causes an increase in the thrust required for axial motion allowing energy to be absorbed by the constant velocity joint 11 and the propeller shaft 26 . The track surface 88 can be tuned to achieve different force levels, allowing for the design of a controlled energy absorption profile within the constant velocity joint 11 . The tuning may be accomplished by changing the size, the shape, the material, or the location of the track surface 88 . The circlips 76 is combined with the track surface 88 as shown in FIG. 5A is optional and is not required.
In addition or in the alternative, the track surface 89 having a taper 91 is longitudinally located in the inner extended axial range IE of an inner ball track 61 of the inner joint part 52 . There can be one or more track surfaces 89 located on anyone of the other inner ball tracks 61 . The taper 91 may extend linearly over the inner extended axial range IE as shown in the layout view of FIG. 7 . Alternatively, the track surface may have a variable taper or a stepped taper of increasing or decreasing size ( FIG. 5B ). Thus, when the connecting shaft 44 along with the inner joint part 52 , the torque transmitting balls 56 , and the ball cage 54 are thrust, as a result of an unintended force, such as a crash, beyond the normal axial range N and into the inner extended axial range IE of the joint 11 , the torque transmitting balls 56 will interfere with or be impeded by the track surface 89 . The impediment of the track surface 89 causes an increase in the thrust required for axial motion allowing energy to be absorbed by the constant velocity joint 11 and the propeller shaft 26 .
Thus, under normal operating conditions, the torque transmitting balls 56 will operate in the normal axial range N of the constant velocity joint 11 . In certain crash situations, however, the connecting shaft 44 along with the inner joint part 52 , the ball cage 54 and the torque transmitting balls 56 will be thrust toward the hollow shaft 42 allowing track energy to be absorb along the outer extended axial range E and or the internal extended axial range IE caused by the impediment of the track surface 88 , 89 upon the outer joint part 50 or inner joint part 52 , respectfully. As is evident from the figures, the track surfaces 88 , 89 may also interfere with the ball cage 54 in the extended ranges E, IE.
The one or more track surfaces 88 , 89 the one or more circlips 76 , the one or more inner energy absorption surfaces 81 and the one or more bore surfaces 82 are combinable to achieve a controlled and tuned energy absorption rate when the constant velocity joint 11 is operated beyond the normal axial range N. The track surfaces 88 , 89 may be made from the same material piece as the outer joint part or inner joint part.
FIG. 6 shows a layout view of an outer ball track 60 according to one embodiment of the present invention. The layout view is representative of an outer ball track 60 having a track surface 88 with a taper 90 located in the extended axial range E of a constant velocity joint 11 . FIG. 7 shows a layout view of an inner ball track 61 according to one embodiment of the present invention. The layout view is representative of an inner ball track 61 having a track surface 89 with a taper 91 located in the inner extended axial range IE of a constant velocity joint 11 .
From the foregoing, it can be seen that there has been brought to the art a new and improved crash-worthy constant velocity joint. While the invention has been described in connection with one or more embodiments, it should be understood that the invention is not limited to those embodiments. On the contrary, the invention covers all alternatives, modifications, and equivalents as may be included within the spirit and scope of the appended claims.
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A constant velocity joint has an outer part, an inner part, a plurality of torque transmitting balls, and a cage having windows for retaining the balls in the ball tracks of the outer and inner parts. The balls are retained in a plane by the cage and guided by corresponding pairs of outer and inner ball tracks. The outer and inner ball tracks form angles of intersection with respect to an axis where the angles are identical in size but set in opposite directions to one another. The outer part and the inner part operate in a normal axial range, there being at least one energy absorption surfaces located in the outer extended axial range or the inner extended axial range. The energy absorption surface interferes with at least one of the torque transmitting balls when the joint is operated beyond said normal axial range.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/903,481, filed on Nov. 13, 2013. The entire disclosure of the above application is incorporated herein by reference.
FIELD
[0002] This invention relates to water treatment by dissolved air floatation and, more particularly, harvesting algae from an open body of water utilizing dissolved air floatation technology.
BACKGROUND
[0003] This section provides background information related to the present disclosure which is not necessarily prior art.
[0004] Dissolved air flotation (DAF) is a water treatment process that clarifies wastewaters (or other waters) by the removal of suspended matter such as oil or solids. The removal is achieved by dissolving air in the water or wastewater under pressure and then releasing the air at atmospheric pressure in a flotation tank or basin. The released air forms tiny bubbles which adhere to the suspended matter causing the suspended matter to float to the surface of the water where it may then be removed by a skimming device.
[0005] Dissolved air flotation is very widely used in treating the industrial wastewater effluents from oil refineries, petrochemical and chemical plants, natural gas processing plants, paper mills, general water treatment and similar industrial facilities. A very similar process known as induced gas flotation is also used for wastewater treatment. Froth flotation is commonly used in the processing of mineral ores.
[0006] The feed water to the DAF float tank is often (but not always) dosed with a coagulant (such as ferric chloride or aluminum sulfate) to flocculate the suspended matter.
[0007] A portion of the clarified effluent water leaving the DAF tank is pumped into a small pressure vessel (called the air drum) into which compressed air is also introduced. This results in saturating the pressurized effluent water with air. The air-saturated water stream is recycled to the front of the float tank and flows through a pressure reduction valve just as it enters the front of the float tank, which results in the air being released in the form of tiny bubbles. The bubbles adhere to the suspended matter, causing the suspended matter to float to the surface and form a froth layer which is then removed by a skimmer. The froth-free water exits the float tank as the clarified effluent from the DAF unit.
[0008] Some DAF unit designs utilize parallel plate packing material, lamellas, to provide more separation surface and therefore to enhance the separation efficiency of the unit.
[0009] DAF systems can be categorized as circular (more efficient) and rectangular (more residence time). The former type requires just 3 minutes; an example is a Wock-Oliver DAF system (www.wockoliver.com). The rectangular type requires 20 to 30 minutes; a typical example is a Syskill DAF system (www.syskill.com.au). One of the bigger advantages of the circular type is its spiral scoop. A typical DAF system is shown in the schematic diagram of FIG. 13 .
[0010] The DAF Corporation (www.dafcorp.com) FC Maximizer clarifier is designed and manufactured for harvesting algae. It is a hybrid DAF clarifier. Algae feeds on carbon dioxide and sun light. Algae's biomass once refined can be used for animal feed or its lipid oil for blended petroleum based fuels. The FC Maximizer clarifier is a cost-effective way to harvest algae. It can also feed algae. Part of the FC Maximizer clarifier system is the AMT air dissolving system. It can be used to nourish algae with a side stream of CO2 as a nutrient. This side stream of carbon dioxide with laden water and compressed air from this AMT is injected into the FC Maximizer clarifier as fine micron bubbles. These micron bubbles rise to the surface of the water in the tank at a rate 10″ to 12″ per minute. Hundreds of millions of all equal sized, fine micron bubbles entrap themselves in the suspended solids or algae bloom in the FC Maximizer tank.
[0011] Parallel with this process, on the open tank top rim is a rotating stainless steel tank carriage that supports the fixed and rotating tank internal parts. A stainless steel, variable speed, two blade rotating scoop is attached to it. Again, this design gently dips and scoops up the dense fine float mat and discharges it into a holding tank. Clean carbon dioxide enriched nutrient water is discharged from the clarifier tank. This water can be piped back into different systems for a multitude of uses.
[0012] The FC Maximizer clarifier is self-cleaning. It operates with minimal turbulence in a shallow round tank. The FC Maximizer clarifier will remove 98% of the algae bloom and lipid oil within the first two and a half minutes. The clarifier's wetted parts are all stainless steel. Sizes ranging from 20 gpm up to 9000 gpm are manufactured.
[0013] However, the prior art does not directly remove algae from open bodies of water on an in-lake basis utilizing dissolved air floatation technology.
SUMMARY
[0014] According to the present invention, the dissolved air floatation (DAF) equipment is mounted on a boat (catamaran or barge configuration) to remove microscopic algae directly from the water in lakes and ponds. One key element in the process is the utilization of DAF equipment. The lake water passes through a channel under the boat that allows for the processing of large volumes of water at low energy costs.
[0015] The boat would collect both algae and phosphorus by using the dissolved air flotation (DAF) technology. DAF uses tiny bubbles to cause algae to float to the surface of the water. The algae then would be skimmed and stored on the harvesting boat. By weight, 3 percent of algae is phosphorous. Therefore, if 100 pounds of algae were removed, three pounds of phosphorus also would be taken out of the body of water.
[0016] The collected algae would be conveyed to a storage facility for processing and/or transport. The algae can be used as a renewable biofuel in several forms. After processing of the algae for its biofuel value, the nutrient rich algal biomass can be used as a sellable, organic product.
[0017] An apparatus for harvesting algae from an open body of water includes a boat having a pair of spaced apart parallel flotation members and a deck disposed on and connected to the members. The spaced apart members define an area therebetween forming a process channel. A separating mechanism disposed on the boat separates the process channel into a plurality of process channel sections arranged in series. The process channel sections are disposed intermediate the flotation members. Each of the process channel sections include a deflector plate, a scum beach, a scum trough, and diffused air piping. The diffused air piping is in fluid communication with a dissolved air flotation system.
DRAWINGS
[0018] The above as well as other advantages of the present invention will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment when considered in the light of the accompanying drawings in which:
[0019] FIG. 1 is a top plan view of an algae harvesting boat according to the invention;
[0020] FIG. 2 is structural framing plan for the boat shown in FIG. 1 ;
[0021] FIGS. 3A and 3B are front and rear views of the boat shown in FIG. 1 ;
[0022] FIG. 4 is a side view of the boat shown in FIG. 1 ;
[0023] FIG. 5A is a side elevational view of the boat shown in FIG. 1 ;
[0024] FIGS. 5B , 5 C are perspective views of the boat shown in FIG. 5 ;
[0025] FIG. 6 is a front left perspective view of the boat shown in FIG. 1 ;
[0026] FIG. 7 is a top plan view of the process channel of the boat shown in FIG. 1 ;
[0027] FIG. 8 is an end elevational view of the process channel shown in FIG. 7 ;
[0028] FIG. 9 is a front left perspective view of the process channel shown in FIG. 7 ;
[0029] FIG. 10 is a front left perspective view of a boat of another aspect of the present disclosure;
[0030] FIG. 11 is a front end elevational view of the boat of FIG. 10 ;
[0031] FIG. 12 is a rear end elevational view of the boat of FIG. 10 ; and
[0032] FIG. 13 is a diagram of a prior art dissolved air flotation system.
DESCRIPTION
[0033] The following detailed description and appended drawings describe and illustrate various exemplary embodiments of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner. In respect of the methods disclosed, the steps presented are exemplary in nature, and thus, the order of the steps is not necessary or critical.
[0034] Referring to FIG. 1 , an algae harvesting boat includes two aluminum members which according to several aspects define pontoons 1 (having exemplary dimensions of 48″ diameter×40′ long) thereby providing flotation members supporting a non-skid deck on an aluminum frame 2 . A 48 ″ wide process channel 3 having multiple individual channel sections is defined by and positioned between the pontoons 1 . Mounted on the deck are a generator unit 4 , an electrical distribution panel 5 , a saturator 6 , a DAF pump 7 , a DAF air compressor 8 , a vacuum pump 9 , multiple algae storage tanks 10 individually receiving material from one of the multiple channel sections, 4″ butterfly valves 11 and oxygenation spray nozzles 12 .
[0035] Referring to FIG. 2 , the structural framing for the boat includes the two aluminum pontoons 1 , the aluminum structural beam framing 2 , and the 48″ wide process channel 3 . Welded deck framing 14 and aluminum channel framing 16 are also provided.
[0036] Referring to FIGS. 3A and 3B , front and rear views respectively of the boat include the two aluminum pontoons 1 , 24″ welded riser sections 18 , 12″ aluminum beam framing 20 , 12″ deck with integral framing 22 , a 42″ safety handrail 24 , a 48″ tall by 96″ wide trash guard 26 at an inlet of the process channel 3 , the generator unit 4 , the saturator 6 , the DAF pump 7 , the DAF air compressor 8 , the vacuum pump 9 , a submersible fountain pump 28 , the 4″ butterfly valves 11 , the algae storage tank 10 , the multiple oxygenation spray nozzles 12 . The trash guard 26 is positioned at the forward end of the process channel 3 and at least partially below a water level 30 to permit entrance of the water containing the algae, but to block large elements from entering the process channel 3 .
[0037] Referring to FIG. 4 , the boat includes the aluminum pontoons 1 , the 24″ welded riser sections 18 , the 12″ aluminum beam framing 20 , the 12″ deck with integral framing 22 , the 42″ safety handrail 24 , the vacuum pump 9 , the multiple 4″ butterfly valves 11 , the algae storage tanks 10 , and the oxygenation spray nozzles 12 .
[0038] Referring to FIGS. 5A-5C , side elevational and sectional views of the boat include the two aluminum pontoons 1 , the 24″ welded riser sections 18 , the 12″ aluminum beam framing 20 , the 12″ deck with integral framing 22 , the 42″ safety handrail 24 , the 48″ wide by 96″ long process channel sections 3 a, 3 b, 3 c, 3 d, the trash guard 26 , the generator unit 4 , the electrical distribution panel 5 , the saturator 6 , the DAF pump 7 , the DAF air compressor 8 , the submersible fountain pump 28 , the oxygenation spray nozzles 12 , the vacuum pump 9 , the algae storage tanks 10 , and the water level 30 .
[0039] Referring to FIG. 6 , in a perspective view of the boat shown are the two aluminum pontoons 1 , the 24″ welded riser sections 18 , 12″ the aluminum beam framing 20 , the 12″ deck with integral framing 22 , the 42″ safety handrail 24 , the trash guard 26 , the generator unit 4 , the electrical distribution panel 5 , the saturator 6 , the DAF pump 7 , the DAF air compressor 8 , the 4″ butterfly valves 11 , the algae storage tanks 10 , and oxygenation spray nozzles 12 .
[0040] Referring to FIG. 7 , the process channel includes ½″ thick (48″×96″) solid vinyl sheeting 32 , a plurality of 2″ SCH80 piping supports 34 , a 1″ thick (48″×96″) solid vinyl baffle 36 , multiple sections of 1″ SCH80 diffused air piping 38 , multiple ½″ thick (24″×48″) deflector plates 40 , multiple ½″ thick (24″×48″) algae scum beaches 42 , and a 12″×12″×48″ solid vinyl scum trough 44 .
[0041] Referring to FIG. 8 , the process channel 3 includes the solid vinyl sheeting 32 , the piping supports 34 , the solid vinyl baffle 36 , the diffused air piping 38 , the deflector plates 40 , the algae scum beach 42 , and the solid vinyl scum trough 44 .
[0042] Referring to FIG. 9 , the process channel including the solid vinyl sheeting 32 , the 2″ SCH80 piping supports 34 , the solid vinyl baffle 36 , the diffused air piping 38 , the deflector plates 40 , the algae scum beach 42 , and the solid vinyl scum trough 44 .
[0043] Referring to FIGS. 10-12 , an algae harvesting boat 50 is modified from the algae harvesting boat of FIG. 1 to include two rectangular-shaped aluminum members which according to several aspects define pontoons 52 , 54 (having exemplary dimensions of 48″ wide×48″ high ×40′ long) which are used in place of the pontoons 1 of FIG. 1 . The pontoons 52 , 54 provide flat upper surfaces for attachment of the components of the system. Other components of algae harvesting boat 50 are substantially the same as the algae harvesting boat of FIG. 1 . The pontoons 52 , 54 provide flotation members supporting a non-skid deck on the aluminum frame 2 ′. The 48″ wide process channel 3 ′ having multiple individual channel sections is defined by and is positioned between the pontoons 52 , 54 . Mounted on the deck are the generator unit 4 ′, the electrical distribution panel 5 ′, the saturator 6 ′, the DAF pump 7 ′, the DAF air compressor 8 ′, the vacuum pump 9 ′, multiple algae storage tanks 10 ′ individually receiving material from one of the multiple channel sections, the multiple 4″ butterfly valves 11 ′ and the multiple oxygenation spray nozzles 12 ′. The trash guard 26 ′ is similarly located at the forward end of the process channel 3 ′.
[0044] With specific reference to FIG. 12 the rectangular-shaped pontoons 53 , 54 provide opposed, planar surfaces 56 , 58 which are substantially parallel to each other. The surfaces 56 , 58 define the inner flow and boundary surfaces of the process channel 3 ′ such that additional framing and components are not required to establish the boundary surfaces of the process channel 3 ′ which may be required with the round pontoons 1 of the embodiment of FIG. 1 . The flat upward facing surfaces of the pontoons 52 , 54 also provide for direct connection of the support structure of the aluminum frame 2 ′.
[0045] In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.
[0046] Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
[0047] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
[0048] When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
[0049] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
[0050] Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
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An apparatus for harvesting algae from an open body of water includes a boat having a pair of spaced apart parallel flotation members and a deck disposed on and connected to the members. The spaced apart members define an area therebetween forming a process channel. A separating mechanism disposed on the boat separates the process channel into a plurality of process channel sections arranged in series. The process channel sections are disposed intermediate the flotation members. Each of the process channel sections include a deflector plate, a scum beach, a scum trough, and diffused air piping. The diffused air piping is in fluid communication with a dissolved air flotation system.
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FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to new tryptophan derivatives and to pharmaceutical compositions comprising them, particularly for the treatment of neoplastic diseases.
Protein tyrosine kinases (PTKS) are members of a growing family of protooncoproteins and oncoproteins that play a pivotal role in normal and abnormal proliferative processes. Enhanced PTK activity has been associated with proliferative diseases such as cancer (Bishop, 1987), atherosclerosis (Ross, 1989) and probably psoriasis (Elder et al., 1989). Correlation between increased PTK activity and a particular pathological condition was demonstrated in mammary and ovarian carcinoma (reviewed in Levitzki, 1992).
One of the ideas to control growth and proliferation of malignant cells in vitro and in vivo is the utilization of cell-permeable blockers of tyrosine kinases (PTK blockers) (Graziani et al., 1981 and 1983). Ideally, a specific inhibitor for each one of the tyrosine kinase involved is desirable. However, a broader specificity may be preferable as more than one family member of these enzymes may be involved in abnormal proliferative processes (Levitzki, 1992).
Conceptually, even in cases in which an enzyme, its substrate and the catalytic mechanism have been well characterized, there is no certain rational approach for designing an enzyme blocker. In spite of the need for PTK-blockers--for basic research and therapeutical purposes, this field has progressed slowly, mainly due to the lack of rational-designing techniques to produce PTK blockers.
Since PTKs are involved in many vital processes, it would be highly desirable to select PTK-blockers arresting neoplastic proliferation but which are less effective in inhibiting normal metabolic signals which are also dependent on endogenous tyrosine kinase activity.
SUMMARY OF THE INVENTION
It has now been found in accordance with the present invention that certain tryptophan derivatives of hydrophobic nature can permeate into cell interiors and inhibit the insulin receptor tyrosine kinase (InsRTK) as well as several related PTKs.
The PTK-blockers of the invention were developed by an approach termed "induced-fit reverse chemical modification" which enables to design a PTK-blocker also if the basic physicochemical features of the enzyme are largely obscured. The method is based on chemical modification and inactivation of the enzyme with a substrate-like reagent followed by modification of the reagent (rather than the enzyme itself) and finally converting it to non-covalent blocker.
Thus, to design and synthesize a low molecular weight blocker of InsRTK able to permeate into cell interiors, we first searched for an affinity reagent that would covalently bind and inactivate the InsRTK at low concentrations. Such a reagent was found to be benzyloxycarbonylphenyl-N-hydroxysuccinimide ester (CBZ-Phe-OSU) that inactivated InsRTK with an IC 50 value=50 μM. Examining the inactivation power of CBZ-Phe-OSU and related analogs, revealed that the modifying reagent should possess (from the N-terminus to the C-terminus side) a small aromatic hydrophobic domain; a big hydrophobic domain and a C-terminus hydrophilic domain. The complementary hydrophilic domain of the InsRTK contains a lysine moiety that reacts covalently with the active ester and is likely to participate in substrate binding or catalysis. Equipped with this information we have synthesized a family of competitive inhibitors.
The present invention thus relates to a compound of formula I: ##STR1## wherein R 1 is a hydrophobic group;
R 2 is --COOH, --SO 3 H or --PO 3 H;
R 3 is H, or phenylthio or pyridythio substituted by one or two NO 2 groups;
n is 1 to 3, and
pharmaceutically acceptable salts thereof.
In the compound of formula I, R 1 is a hydrophobic group enabling permeation of the compound to the cell interior. Examples of suitable hydrophobic groups are C 5 -C 20 alkyl or alkenyl, C 5 -C 20 carboxylic acyl, C 3 -C 8 alkoxycarbonyl, C 5 -C 8 cycloalkoxycarbonyl, and unsubstituted or substituted benzyloxycarbonyl.
Suitable "C 5 -C 20 , alkyl" groups according to the invention include, but are not limited, to the following: straight and branched pentyl, hexyl, octyl, dodecyl, etc. The groups "C 5 -C 20 alkenyl" include, but are not limited to, straight and branched pentenyl, hexenyl, octenyl, dodecenyl, etc. The radicals "C 5 -C 20 carboxylic acyl" herein refers to saturated or unsaturated, straight or branched chain radicals including, but not being limited to, valeryl, caproyl, capryl, lauryl, myristil, palmitoyl, stearoyl, arachidoyl, palmitoleyl, oleyl, etc. "C 3 -C 8 alkoxycarbonyl" herein refers to straight or branched radicals including, but not being limited to, isopropoxycarbonyl, t-butoxycarbonyl (t-Boc), t-amyloxycarbonyl, pentoxycarbonyl, hexoxycarbonyl, etc. "C 5 -C 8 cycloalkoxycarbonyl" radicals include cyclopentoxycarbonyl, cyclohexoxycarbonyl, cycloheptyloxycarbonyl and cyclooctyloxycarbonyl. "Substituted benzyloxycarbonyl" groups include, but are not limited to, o-chlorobenzyloxycarbonyl, p-chlorobenzyloxycarbonyl and 2,4- and 2,6-dichlorobenzyloxycarbonyl.
In preferred embodiments according to the invention, R 1 is benzyloxycarbonyl (carbobenzoxy, denoted herein as CBZ) or t-butoxycarbonyl (t-Boc) and R 2 is --SO 3 H. Some of these compounds are shown in Scheme I herein with their chemical formulas and respective designations as used herein in the specification. In a still more preferred embodiment, the invention relates to the compound in which R 1 is carbobenzoxy, R 2 is SO 3 H, R 3 is 2,4-dinitrophenylthio and n is 2 herein designated as CBZ-DNPS-TRP-TAU.
__________________________________________________________________________SCHEME IDerivative designation Structure__________________________________________________________________________L-tryptophan ##STR2##AC-TRP-TAU ##STR3##CBZ-TRP-β-TAU ##STR4##CBZ-TRP-TAU ##STR5##CBZ-NPS-TRP-TAU ##STR6##CBZ-DNPS-TRP-TAU ##STR7##__________________________________________________________________________
Any pharmaceutically acceptable salt of the compounds of formula I with organic or inorganic bases may be used according to the invention, such as sodium salts.
The compounds of formula I are prepared by a process comprising reaction of R 1 -L-tryptophan-N-hydroxysuccinimide with a compound R 2 --(CH 2 ) n --NH 2 , thus obtaining a compound of formula I in which R 3 is H, which is optionally further reacted with a compound of formula R 3 --Cl to produce compounds in which R 3 is other than hydrogen. Thus, for example, the above compound CBZ-DNPS-TRP-TAU is prepared by first reacting carbobenzoxy-L-tryptophan-N-hydroxy-succinimide ester (CBZ-TRP-OSU) with taurine (TAU), and the resulting CBZ-TRP-TAU compound is reacted with 2,4-dinitrophenylsulfenyl chloride (2,4-DNPS-Cl). By substituting taurine with other suitable amino sulfonic, amino carboxylic or aminophosphonic acids, other derivatives of formula I are obtained.
The compounds of formula I are useful for basic research on protein tyrosine kinases. They may be further used as active ingredients of pharmaceutical compositions for the treatment of cancer, together with pharmaceutically acceptable carriers. Cancers that can be treated with the compounds of the invention are those with high rate of proliferation, e.g., non-Hodgkins lymphomas of B- or T-cell origin and most types of leukemia. In addition, the compounds of formula I may be efficient in blocking fast spreading metastasis of solid tumors, e.g., breast cancer, rectocolon cancer and lung cancer, and in the disseminated phase of malignant melanoma. The compositions will be administered by any suitable way, e.g., by injection, in a dose to be established by the specialists depending on the age of the patient and gravity of the disease. Doses of from 3 mg/kg body weight to 10 mg/kg body weight can be used.
In a further embodiment, the invention relates to a method of treatment of a patient afflicted with a neoplastic disease which comprises administering to said patient an effective amount of a compound of formula I.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows dose-dependent inhibition of insulin receptor tyrosine kinase (InSRTK)-mediated PolyGlu 4 Tyr phosphorylation by the compound herein designated CBZ-DNPS-TRP-TAU.
FIG. 2 shows dose-dependent inhibition of insulin- (empty circles) or vanadate- (filled circles) stimulated lipogenesis by CBZ-DNPS-TRP-TAU.
FIG. 3 shows inhibition of insulin-dependent proliferation of murine T-cell lymphoma (LB3) by CBZ-DNPS-TRP-TAU.
FIG. 4 shows inhibition of LB3 cell proliferation by CBZ-DNPS-TRP-TAU in response to various mitogens: empty squares--phorbol ester (PMA); empty losanges--insulin; filled losanges-interleukin-2 (IL-2); filled circles--growth hormone.
DESCRIPTION OF PREFERRED EMBODIMENTS
The invention will now be illustrated by the following non-limiting examples.
EXAMPLE 1
Synthesis of CBZ-DNPS-TRP-TAU
I. Synthesis of CBZ-TRP-TAU
870 mg (2 eq) of CBZ-L-tryptophan-N-hydroxysuccinimide ester (CBZ-TRP-OSU) were dissolved in 20 ml of dimethylsulfoxide (DMSO). Taurine (TAU, 2-aminoethylsulfonic acid (124 mg, 1 eq) and NaHCO 3 (168 mg, 2 eq) were dissolved in 20 ml of water. The solutions were then mixed quickly and allowed to react for 7 hours at room temperature. Water (200 ml) was then added and the reaction mixture was lyophilized to dryness.
The residue was dissolved in 140 ml of water. The suspension was brought to pH 3.0 by adding the proper amount of HCl and extracted with ethyl acetate (EtAc). Extraction was repeated 4-7 times, until no absorbance at 280 nm was detected in the EtAc fraction. The aqueous solution was lyophilized; CBZ-TRP-TAU is highly soluble in H 2 O (up to a concentration of 1.3M). Molar extinction coefficient ε 280 nm =5500 at neutral pH value. It contains one to one (molar ratio) of tryptophan to taurine as determined by absorbance at 280 nm and amino acid analysis following acid hydrolysis.
II. CBZ-DNPS-TRP-TAU
CBZ-TRP-TAU (final concentration=5 mM in 200 ml, 98% glacial acetic acid) was allowed to react with 2 equivalents of 2,4-dinitrophenylsulfenyl chloride (2,4 DNPS-Cl) for several hours at room temperature. Excess reagents were then centrifuged down, and acetic acid evaporated. The residue was dissolved in 200 ml of 0.1M NaOH and centrifuged again. The clear solution was extracted with EtAc, several times. Before each extraction the aqueous phase was adjusted to pH 10 and reextracted (This procedure was applied since in preliminary experiments it was found that CBZ-DNPS-TRP-TAU (but not CBZ-TRP-TAU) is extractable to ethyl acetate at alkaline pH values). The EtAc fractions were pooled together, dried by sodium sulphate and evaporated. The residue was suspended in H 2 O and lyophilized, thus obtaining the title product. CBZ-DNPS-TRP-TAU is soluble in H 2 O (up to a concentration of 2 mM) and in DMF, or DMSO (at 20 mM concentration). It has molar extinction coefficients (in 20% acetic acid) with maxima at 280 nm (ε 280 nm =33,400) and at 360 nm (ε 360 nm =16,000). Amino acid analysis (after acid hydrolysis) revealed nearly 1 to 1 molar ratio of taurine to DNPS-TRP. IC 50 value=0.13 mM.
EXAMPLE 2
Synthesis of CBZ-DNPS-TRP-aminomethylsulfonic acid and CBZ-DNPS-TRP-aminopropylsulfonic acid were carried out according to the basic procedure of Example 1, except that aminomethylsulfonic acid, or 3-amino,1-propane sulfonic acid were used, respectively, instead of taurine.
Synthesis of tBoc-DNPS-TRP-aminomethylsulfonic acid, tBoc-DNPS-TRP-aminoethylsulfonic acid, and tBoc-DNPS-TRP-aminopropylsulfonic acid were performed by the same basic procedure but starting from tBoc-TRP-OSU, and coupling it to either aminomethyl-, aminoethyl- or aminopropylsulfonic acid.
EXAMPLE 3
Dose-dependent inhibition of insulin receptor tyrosine kinase (InsRTK)-mediated PolyGlu 4 Tyr phosphorylation by CBZ-DNPS-TRP-TAU
An assay of PolyGlu 4 Tyr phosphorylation by partially purified insulin receptor was run for 30 min at 22° C. in 60 μl of 50 mM Hepes (pH 7.4)-0.1% Triton X-100 containing wheat-germ-agglutinin purified rat liver insulin receptor (1 μg protein), MgCl 2 25 mM; MnCl 2 , 1 mM, ATP 17 μM, insulin 0.1 μM, PolyGlu 4 Tyr, 0.17 mg/ml and the indicated concentrations in FIG. 1 of CBZ-DNPS-TRP-TAU. Phosphotyrosine content in PolyGlu 4 Tyr was determined by a radioimmunoassay procedure (Shisheva et al., 1991). As shown in FIG. 1, CBZ-DNPS-TRP-TAU blocks InsRTK-dependent substrate phosphorylation in cell-free experiments (IC 50 value=130 μM). The inhibitory potency of other derivatives of formula I on InsRTK-catalyzed PolyGlu 4 Tyr phosphorylation in cell-free experiments was determined. CBZ-NPS-TRP-TAU: IC 50 value=0.55 mM; CBZ-TRP-TAU: IC 50 value=2.7 mM; CBZ-TRP-β-TAU: IC 50 value=3.5 mM. For comparison, the IC 50 values for AC-TRP-TAU and L-tryptophan are 5 mM and >30 mM, respectively.
EXAMPLE 4
Dose-dependent inhibition of insulin- or vanadate-stimulated lipogenesis by CBZ-DNPS-TRP-TAU in rat adipocytes
Rat adipocytes were prepared essentially by the method of Rodbell, 1964. The fat pads of three rats were cut into small pieces with scissors and digested in 3 ml of Krebs-Ringer-Bicarbonate (KRB)-buffer containing 0.7% bovine serum albumin (BSA) (pH 7.4) with collagenase (1 mg/ml). The digestion was performed in a 25 ml flexible plastic bottle under an atmosphere of carbogen (95% O 2 , 5% CO 2 ) for 40 min at 37° C. with vigorous shaking. Five ml of buffer was then added, and the cells were squeezed through a mesh screen. The cells were then allowed to stand for several minutes (in a 15 ml plastic test tube at room temperature, floating) and the buffer underneath was removed. This procedure (suspension, floating and removal of buffer underneath) was repeated three times. For 14 C-U!glucose incorporation (lipogenesis), the fat cell suspensions (3×10 5 cells/ml) were divided into plastic vials (0.5 ml per vial) and incubated for 60 min at 37° C. under an atmosphere of 95% O 2 , 5% CO 2 , with 0.2 mM U- 14 C!glucose, in either the presence or absence of insulin (100 ng/ml) and the indicated concentrations in FIG. 2 of CBZ-DNPS-TRP-TAU. The reaction was terminated by adding toluene-based scintillation fluid (1.0 ml per vial) and the extracted lipids were counted (Shechter and Karlish, 1980). Fat cell suspensions were pre-incubated for 20 min at 37° C. with increasing concentrations of the inhibitors. Results are expressed in FIG. 2 as the percent of maximal stimulation at the indicated concentrations of inhibitors. In all experiments insulin-stimulated lipogenesis was 4- to 5-fold higher than basal; basal ˜2000 cpm per 3×10 5 cells/h; V insulin 8000-10,000 cpm per 3×10 5 cells/h.
As shown in FIG. 2, CBZ-DNPS-TRP-TAU blocks insulin-dependent biological responses (such as lipogenesis) in intact rat adipocytes (IC 50 =170 μM). Comparison of the dose-dependent inhibitions in cell-free system (FIG. 1) and in intact cellular system (FIG. 2) indicates that CBZ-DNPS-TRP-TAU exerts excellent permeability via the hydrophobic plasma membrane of mammalian cells into the cell interior. CBZ-DNPS-TRP-TAU also blocks the insulin-like effects of vanadate ions (IC 50 =45 μM). The insulin-like effects of vanadium are mediated via another (non-insulin-receptor) cytosolic tyrosine kinase in rat adipocytes (Shisheva and Shechter, 1993).
EXAMPLE 5
Lack of inhibition of CBZ-DNPS-TRP-TAU on isoproterenol-mediated lipolysis
In general there are two classes of protein kinases (PKs) in mammalian tissues: (a) PKs which phosphorylate tyrosine moieties in proteins (to phosphotyrosine), and (b) PKs which phosphorylate serine and threonine moieties (to phosphoserine and phosphotreonine). We wanted to confirm that CBZ-DNPS-TRP-TAU does not inhibit metabolic effects which are dependent on serine and threonine specific protein kinases. An example for such a metabolic effect is lipolysis which depends on protein kinase A. Rat adipocytes (prepared by the method of Rodbell, 1964) were incubated with isoproterenol alone (1 μM) or isoproterenol with CBZ-DNPS-TRP-TAU (200 μM) for one hour at 37° C. The amount of glycerol released from the cells was then determined by spectroscopic procedure (Shechter, 1982). As can be seen in Table I, CBZ-DNPS-TRP-TAU has negligible effect in inhibiting this metabolic effect.
TABLE I______________________________________Lack of inhibitory effect of CBZ-DNPS-TRP-TAU onisoproterenol-mediated lipolysis. Amount of glycerol released PercentAdditions (nmol/3 × 10.sup.5 cells/3 h) lipolysis______________________________________None 10 0Isoproterenol, 1 μM 165 100Isoproterenol, 1 μM plus 154 93CBZ-DNPS-TRP-TAU(200 μM)______________________________________
EXAMPLE 6
Inhibition of insulin-dependent proliferation of murine T-cell lymphoma (LB3) by CBZ-DNPS-TRP-TAU
LB cells were removed from the peritoneal cavity of BALB/c mice, washed and resuspended in RPMI-1640. Then a continuous line designated LB3 was established in "LB medium" (50% RPMI-1640 plus 50% DCCM-1 in 10% fetal calf serum (FCS)). The LB3 cells were incubated (37° C., 5% CO 2 ) in microplate wells (Nunc, Roskilde, Denmark) with 0.2 ml RPMI-1640 alone and in the same medium containing insulin, fetal calf serum (FCS) or both, and different concentrations of the compound CBZ-DNPS-TRP-TAU as indicated in FIG. 3. Proliferation capacity was determined by thymidine incorporation ( 3 H-TdR, 1 μCi/well, specific activity 5 Ci/mM), added to the cells 24 hours later. In a typical experiment, cpm of 3 H-thymidine incorporated into 30,000 cells was 12-14 fold higher in the presence of insulin or other mitogens than in their absence.
As shown in FIG. 3, CBZ-DNPS-TRP-TAU blocks insulin-dependent proliferation of murine T-cell lymphoma. Inhibition occurred with IC 50 =0.95 μM, a concentration range nearly 200 times lower than that required to inhibit normal metabolic biological effects of insulin (see FIG. 2).
EXAMPLE 7
Inhibition of LB3 cell proliferation by CBZ-DNPS-TRP-TAU in response to various mitogens
Experimental conditions were as described in Example 6 except that lower concentrations of mitogens were applied here (those triggering 50% of maximal proliferation): insulin, interleukin-2 (IL-2), growth hormone and PMA. PMA is an activator of protein kinase C. Protein kinase C in this cell type triggers proliferation by a pathway which is only partially dependent on endogenous tyrosine phosphorylation.
As shown in FIG. 4, CBZ-DNPS-TRP-TAU also blocks IL-2 and growth hormone-dependent proliferation of the T-cell lymphoma. Both agents utilize endogenous (cellular) tyrosine kinase activity to mediate their biological effects. In contrast, protein kinase C-dependent proliferation is inhibited by CBZ-DNPS-TRP-TAU at significantly higher concentrations.
In summary, the above examples show that CBZ-DNPS-TRP-TAU exhibits excellent permeability into cell interiors. Its inhibitory potency against malignant proliferation is ˜200-fold greater as compared to its efficacy in arresting normal anabolic processes, both of which are dependent on endogenous tyrosine phosphorylation.
EXAMPLE 8
Relative potencies of various derivatives in cell-free and intact cell systems
Various derivatives according to the invention in which R 1 is benzyloxycarbonyl (CBZ) or t-butoxycarbonyl (t-Boc), R 2 is --SO 3 H or --PO 3 H, n is 1,2 or 3, and R 3 is H, 2-nitrophenylthio (NPS) or 2,4-dinitrophenylthio (DNPS) were prepared and examined in cell-free and intact cell systems. The cell-free assay is PolyGlu 4 Tyr phosphorylation by partially purified insulin receptor as described in Example 3. The assay in intact cells (namely, lipogenesis) was carried out as described in Example 4.
The results in Table II demonstrate that sulfonates (R 2 is SO 3 H) are at least 10 fold more effective than phosphonates (R 2 is --PO 3 H) or carboxylates (R 2 is --COOH for example, CBZ-DNPS-TRP-Aspartic Acid). Also, both in vitro and in vivo, DNPS-TRP derivatives are more potent than NPS-TRP derivatives, which are more potent than non-substituted TRP derivatives (R 3 is H) and than leucine derivatives used for comparison.
The R 1 radical has to be a group conveying desirable hydrophobicity. Thus, although acetyl-DNPS-TRP-TAU inhibits InSRTK in cell-free experiments, it is not suitable because it exhibits low permeability into cell interiors.
TABLE II______________________________________Relative potencies of various derivatives in cell freeand in intact cell systems. Relative cell-free potency in inhibiting Permeability InsRTK into cellDerivative designation % interiors______________________________________CBZ-DNPS-TRP-Taurine 100 excellentCBZ-DNPS-TRP-aminomethyl-SO.sub.3 90 excellentCBZ-DNPS-TRP-aminopropyl-SO.sub.3 70 excellentCBZ-NPS-TRP-Taurine 30 goodtBoc-DNPS-TRP-Taurine 95 excellenttBoc-DNPS-TRP-aminomethyl-SO.sub.3 80 excellenttBoc-DNPS-TRP-aminopropyl-SO.sub.3 90 excellentAcetyl-DNPS-TRP-Taurine 80 poorCBZ-TRP-Taurine 20 poorCBZ-TRP-aminomethyl-PO.sub.3 5 poorCBZ-leucine-Taurine 2 poorCBZ-DNPS-TRP-Aspartic Acid 5 good______________________________________
EXAMPLE 9
BALB/c mice were inoculated intraperitoneally (i.p.) each with 100 LB3 cells. Thirty minutes later the mice were injected i.p. with 50-200 μM of the compound of formula I (e.g. CBZ-DNPS-TRP-TAU), and the injections were repeated every other day for 3 weeks. Control mice were inoculated with LB3 cells only. At the end of the experiment, the survival time of the treated mice is determined.
REFERENCES
Bishop, J. M. (1987) The molecular genetics of cancer. Science 335, 305-311.
Elder et al. (1989) Science 243, 811-814.
Graziani, Y. Chayoth, R., Karny, N., Feldman, B. and Levy, J. (1981) Biochim. Biophys. Acta 714, 415-421.
Graziani, Y., Erikson, E. and Erikson, R. L. (1983) Eur. J. Biochem. 135, 583-589.
Levitzki, A. (1992) FASEB J. 6, 3275-3282.
Rodbell, M. (1964) J. Biol. Chem. 239, 375-380.
Ross, T. (1989) Platelet derived growth factor. Lancet 1, 1179-1182.
Shechter, Y. (1982) Endocrinology 110, 1579-1583.
Shisheva, A. and Shechter, Y. (1993) J. Biol. Chem. 268, 6463.
Shisheva, L. A., Leithner, O. and Shechter, Y. (1991) J. Biol. Chem. Methods 23, 307-314.
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Tryptophan derivatives substituted by a hydrophobic group, e.g. carbobenzoxy, at the N-terminus, and a hydrophilic group, e.g. --COOH, --SO 3 H or --PO 3 H, at the C-terminus, were found to be cell-permeable blockers of protein tyrosine kinases (PTKs). These PTK blockers are useful in basic research and in the treatment of neoplastic diseases.
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This is a divisional of application Ser. No. 09/536,937 filed on Mar. 27, 2000, now U.S. Pat. No. 6,427,776.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for removing sand and other debris from a wellbore; more particularly, the invention relates to apparatus and methods for use in a wellbore utilizing a venturi.
2. Background of the Related Art
In the production of oil and gas, sand breaks loose from oil producing formations and is carried into the wellbore with production fluid. As the production rate of oil increases, the formation sand which breaks loose and enters the wellbore also increases. Over time, the wellbore can become filled and clogged with sand making efficient production of the well increasingly difficult. In addition to sand from the formation, other debris including scale, metal, shavings and perforation debris collects in the wellbore and interferes with production.
One method of removing debris from a wellbore involves the introduction of liquid which is circulated in the well. For example, liquid can be pumped down the wellbore through a pipe string and convey debris to the surface of the well upon return through an annulus formed between the pipe string and the wall of the wellbore. Nitrogen or some other gas can be added to the liquid to create a foam for increasing the debris carrying ability of the liquid. However, a relatively small amount of debris is actually conveyed to the well surface and removed in this manner because of the relatively large volume of space in a wellbore that must be filled with sand bearing liquid.
Another prior art method for removing debris from a well includes lowering a container into the well which is filled with debris and then removed. Typically, the container is sealed at the well surface and an atmospheric chamber formed therein. When the chamber is lowered into the well and opened, the pressure differential between the interior of the container and the wellbore causes the wellbore contents, like debris to be surged into the container. While this method of debris removal is effective, the amount of debris removed is strictly limited by the capacity of the container and in practice is typically not more than 85% of the chamber volume. Additionally, the container must be continuously lowered into the well, filled due to pressure differential, raised from the well and emptied at the well surface.
More recently, a nozzle or other restriction has been utilized in the wellbore to increase circulation of a liquid and to cause, by low pressure, a suction thereunder to collect or “bail” debris. The use of a nozzle in a pressurized stream of fluid is well known in the art and operates according to the following principles: The nozzle causes pressurized liquid pumped from the surface of the well to assume a high velocity as it leaves the nozzle. The area proximate the nozzle experiences a drop in pressure. The high velocity fluid from the nozzle is diverted out of the tool and the low pressure area creates a vacuum in the tool below the nozzle, which can be used to create a suction and pull debris from a well along with fluid returning to the high velocity stream. By the use of a container, the debris can be separated from the flow of fluid, collected and later removed from the well. A prior art tool utilizing a nozzle and a diverter is illustrated in FIG. 1 . The device 100 includes a nozzle portion 105 , a diverter portion 110 , a container 120 for captured debris and one way valve 125 to prevent debris from returning from the tool to the wellbore 130 . A filter is provided above the container but is designed to prevent the passage of particles larger than grains of sand. While the fluid pumped through the nozzle creates a low pressure and suction therebelow, this design is only marginally effective and the suction created in the tool results in only a partially filled container of debris. For example, experiments measuring the effectiveness of the prior art design of FIG. 1 have resulted in a measured suction of only 3-5″ of mercury.
Another apparatus for the removal of debris utilizes a venturi like the one illustrated in prior art FIG. 1 . In additional to the nozzle, the venturi includes a throat portion and a diffuser portion to more effectively utilize the high velocity fluid to create a low pressure area and a suction therebelow. The apparatus of the ' 116 publication, like the device of FIG. 1 also includes a container for holding captured debris wherein the debris enters a flapper valve at the bottom of the container which fills with debris due to suction created by the venturi and is later removed from the well to be emptied at the well surface. While this arrangement is more effective than the one illustrated in FIG. 1, the mechanism is complex and expensive since each part of the device is specially fabricated and the parts are not interchangeable. Most importantly, the nozzle provided with the device is often too small to pass debris carried by the power fluid, clogging the nozzle and making the device useless. Additionally, the size of the container in the prior art devices is fixed limiting the flexibility of the tools for certain jobs requiring large capacity containers.
Aside from simply clearing debris to improve flow of production fluids, debris removal tools can be used to clear debris that has collected in a wellbore over the top of a downhole device, exposing the device and allowing its retrieval and return to the well surface. For example, a bridge plug may be placed in a wellbore in order to isolate one formation from another or a plug maybe placed in a string of tubular to block the flow of fluid therethough. Any of these downhole devices can become covered with debris as it migrates into the wellbore, preventing their access and removal. Removing the debris is typically done with a debris removal device in a first trip and then, in a separate trip, a device retrieval tool is run into the well. This process is costly in terms of time because of the separate trips required to complete the operation.
Debris removal is necessary in any well, whether live and pressurized or dead. In a live well, problems associated with the prior devices are magnified. Circulating fluid through a live well requires a manifold at the well surface to retain pressure within the wellbore. Use of an atmospheric chamber in a live well requires a pressure vessel or lubricator at the well surface large enough to house the atmospheric chambers.
There is a need for debris removal tool utilizing a high velocity fluid stream which effectively removes debris from a wellbore. There is a further need for a debris removal tool that can utilize interchangeable parts depending upon the quality of debris to be removed. There is a further need for a device retrieval tool which can also be used in a single trip to retrieve a downhole device as well as remove debris. There is yet a farther need for a debris removal tool with an adjustable container formed of coiled tubing. There is a further need for a method of debris removal and device retrieval in a live well.
SUMMARY OF THE INVENTION
The present invention provides a simple debris removal apparatus for use in a wellbore. In one aspect of the invention a modular, interchangeable venturi is provided which can be retrofit into an existing debris bailer having a filter and a debris collection container. The venturi module replaces a simple and ineffective nozzle and results in a much more effective bailing apparatus. In another aspect of the invention, a venturi is utilized to create a negative pressure in a wellbore sufficient to actuate a retrieval tool for a downhole device. In yet another aspect of the invention, a combination tool is provided which can evacuate debris in a wellbore, thereby uncovering a downhole device which can then be removed in a single trip. In yet another aspect of the invention, a debris removal apparatus is provided with a method for utilizing the apparatus in a wellbore on coiled tubing. In yet another aspect of the invention a debris removal apparatus is provided which can be run on coiled tubing in a live well using a method of selective isolation and pressure bleed off. In yet another aspect, the invention utilizes a section of coiled tubing for a debris container whereby the coiled tubing can be sized depending upon the amount of debris to be removed in the operation.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.
It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is a prior art debris removal tool having a simple nozzle to increase velocity of a fluid therein to create a suction in the tool therebelow.
FIG. 2 is a section view of the debris removal tool of the present invention showing a venturi in a diverter portion in the tool.
FIG. 3 is an enlarged view of the venturi portion of the tool showing the flow direction of fluid therethrough.
FIG. 4 is a section view showing one dimensional design of the venturi portion of the tool.
FIG. 5 is a section view showing one dimensional design of the venturi portion of the tool.
FIG. 6 is a section view showing one dimensional design of the venturi portion of the tool.
FIG. 7 is a section view showing one dimensional design of the venturi portion of the tool.
FIG. 8 is a section view of the present invention including a retrieval tool disposed at a lower end thereof.
FIG. 9 is a section view of the retrieval tool in an actuated, retracted position.
FIG. 10 is a section view of the retrieval tool in a un-actuated, extended position.
FIG. 11 depicts the debris removal tool of the present invention with coiled tubing disposed therein as a debris container.
FIG. 12 is the tool of FIG. 11 with a spoolable, double valve disposed within the length of coiled tubing and a retrieval tool disposed at the lower end of the tubing.
FIG. 13 is a section view showing a wellhead with a lubricator thereabove and a device retrieval tool disposed therein, the lubricator being installed on the wellhead.
FIG. 14 is a section view of the wellhead with the lubricator installed thereupon, the lubricator being pressurized to the pressure of the wellbore.
FIG. 15 is a section view of the wellhead with a blind ram opened, the retrieval tool having been lowered in the well and a double valve in the coiled tubing string in the lubricator.
FIG. 16 is a section view of the wellhead with a lower pipe ram in a closed position and the lubricator pressurized to atmospheric pressure.
FIG. 17 is a section view illustrating the wellhead with the lubricator having been lifted therefrom exposing the double valve and the coiled tubing severed thereabove.
FIG. 18 is a section view of the wellhead with debris removal tool inserted into the coiled tubing string and an access port installed therebelow.
FIG. 19 is a section view of the wellhead with the coiled tubing in the lubricator having been reattached to the coiled tubing in the wellhead, the upper pipe ram closed and the lubricator pressurized to the pressure of the wellbore.
FIG. 20 is a section view of a wellhead, the access port pressurized to the pressure of the wellbore and the upper and lower pipe rams opened.
FIG. 21 is a section view of the wellhead after the debris removal and device retrieval is completed, the debris removal tool raised into the lubricator and the double valve housed within the access port.
FIG. 22 is a section view of the wellhead wherein the upper and lower pipe rams have been closed and the access port has been pressurized to atmospheric pressure.
FIG. 23 is a section view of the wellhead showing a blind flange removed from the access port and the double valve adjusted to the closed position.
FIG. 24 is a section view of the wellhead showing the lubricator pressurized to atmospheric pressure and, thereafter, the upper pipe ram opened.
FIG. 25 is a section view of the wellhead showing the lubricator and debris removal tool removed from the wellhead, the coiled tubing severed above the double valve.
FIG. 26 is a section view of the wellhead showing the lubricator with the debris removal tool having been removed therefrom and a length of coiled tubing disposed within for connection to the coiled tubing extending from the wellhead therebelow.
FIG. 27 is a section view of the wellhead showing the lubricator pressurized to the pressure of the wellbore and thereafter, the lower pipe ram opened.
FIG. 28 is a section view of the wellhead showing the retrieval tool with the retrieved device lifted from the well and disposed within the lubricator.
FIG. 29 is a section view of the wellhead showing a blind ram in a closed position.
FIG. 30 is a section view of the wellhead showing the lubricator with the retrieval tool and retrieved device disposed therein and removed from the wellhead.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 2 is a section view of a debris bailer tool 200 of the present invention. The tool includes an upper portion 205 , a venturi portion 210 , a diverter portion 215 , a debris screen or filter portion 220 and a debris container 225 including a flapper or ball valve 230 at a lower end thereof. The filter portion 220 is replaceable and is designed to separate debris as small as sand particles from return fluid passing from the container to the venturi portion. In the one embodiment for example, the filter removes particles as small as 8 microns. Depending upon well conditions and the needs of the operator, the screen can be sized for the debris expected to be encountered in the wellbore as well as the type of fluid in the wellbore. For example, some drilling muds will clog a fine screen, but will flow easily through a screen with larger openings therein. The tool 200 operates by the injection of fluid into the upper portion 205 where the fluid travels to the venturi portion 210 and the velocity of the fluid increases as it passes through the nozzle and is then diverted outside of the tool. In the preferred embodiment, the upper portion of the venturi is threaded allowing easy replacement of the venturi for different debris removal operations or a retro fitting of the venturi portion into a prior art tool like the one shown in FIG. 1 . FIG. 3 is an enlarged view of the venturi portion of the tool. The venturi includes a nozzle 211 , throat 212 and a diffuser 213 .
According to the principals of a venturi device, high pressure power fluid passing through the nozzle has its potential energy (pressure energy) converted to kinetic energy in a jet of fluid at high velocity. The power fluid can be made up of a liquid like water or a foam or even a gas. Well fluid mixes with the power fluid in a constant area throat and momentum is transferred to the well fluid, causing an energy rise in the well fluid. As the mixed fluids exit the throat, they are still at the high velocity, and thus contain substantial kinetic energy. The fluids are slowed in an expanding area diffuser that converts the remaining kinetic energy to static pressure sufficient to lift fluids and with them debris, to a containment member in the tool. The arrows 214 in FIG. 3, illustrate the flow of fluid through and around the venturi. Return fluid is recirculated into the nozzle through ports 304 . In a well setting, the device creates a vacuum and fluid and debris are drawn into the container portion of the tool.
FIGS. 4-7 are section views of the venturi portion of the device and illustrate a variety of physical nozzle, throat return port and diffuser sizes to determine flow rates therethrough. In every example, the venturi 300 includes a nozzle 301 , a throat 302 and a diffuser 303 portion. If a throat size is selected such that the area of the nozzle is 60% of the throat area, a relatively high head, low flow rate will result. Adversely, if a throat is selected such that the area of the nozzle is only 20% of the throat area, more well fluid flow is possible. However, since the nozzle energy is being transferred to a large amount of production compared to the power fluid rate, lower heads will be developed. Design variables include the size of the nozzle and throat and the ratios of their flow areas, as well as component shapes, angles, lengths, spacing, finishes and materials. Through selection of appropriate flow areas and ratios, the venturi configuration can be optimized to match well conditions. Most importantly, a nozzle size can be selected to pass debris that may be present in the power fluid.
FIG. 8 is a section view of the present invention including a retrieval tool disposed at a lower end thereof. The retrieval tool 400 is installed at the end of the debris removal tool 200 and relies upon the same venturi forces for operation as are utilized by the debris removal tool 200 . Retrieval tools are well known in the art and are used to retrieve downhole devices like plugs, bridge plugs and packers that have been fixed temporarily in the wellbore but are designed for removal and are fitted with some means for attachment to a retrieval tool. The combined apparatus including the debris removal tool 200 and retrieval tool 400 are run into a well together in order to clear debris from the surface of a downhole device in the wellbore and then retrieve the device and bring it back to the surface of the well. The apparatus of the invention allows both of these operations to be completed in one time-saving trip into the wellbore.
FIGS. 9 and 10 are section views showing the retrieval tool 400 in its actuated (FIG. 9) and un-actuated (FIG. 10) positions. The tool 400 includes an outer body 405 , a slidable member 410 and a collet member 415 disposed between the outer body 405 and the slidable member 410 . The collet member 415 is equipped with fingers at a downhole end. Fingers 420 are designed to flex inward when the tool is actuated and to be prevented from inward flexing by the slidable member 410 when the tool is in the extended position. A biasing member 425 biases the slidable member in a normally extended, position as depicted in FIG. 10 . In order to actuate the tool 400 and cause it to assume the retracted position shown in FIG. 9, a venturi device thereabove as depicted in FIG. 8 is operated creating a suction therebelow. The suction, in addition to gathering debris into the container as herein described, can also act upon a piston surface 430 formed at the downhole end of the retrieval tool, causing the inner member 410 to act against the biasing member 425 and the tool to assume a retracted position.
In operation, the retrieval tool 400 is run into the well along with the debris removal tool 200 . At a predetermined depth where debris is encountered, the debris removal tool 200 is operated and the debris removed from the wellbore and urged into the container 120 of the debris removal tool 200 . Throughout this operation, the retrieval tool 400 will be in an actuated, retracted position as shown in FIG. 9, its inner member urged upwards against the biasing member 425 by the suction force created in the debris removal tool 200 thereabove. After the debris has been contained and a downhole device 450 exposed for retrieval, the retrieval tool 400 , still in the actuated position, is inserted into a receiving member of the downhole device. Typically, the receiving member of the downhole device will include at least one profile 451 formed therein to interact with the fingers 420 of the retrieval tool 400 . The fingers 420 easily flex in order for the retrieval tool 400 to be inserted into the device 450 . Thereafter, the venturi device stops operating and the retrieval tool 400 returns to its normally extended position, preventing the fingers from flexing inward and locking the retrieval tool to the downhole device. The device 450 can then be removed by upward or rotational force or a combination thereof and raised to the top of the well along with the tools 200 , 400 .
In the embodiment described, the retrieval tool operates by communicating with a profile formed upon the inner surface of the downhole device. However, the tool could also operate with a downhole device having a profile formed on the outside thereof. In this case, the collet fingers would be prevented from inward flexing movement by the inner member.
Use of the debris removal tool of the present invention can be performed using a predetermined and measured length of coiled tubing as a debris container, whereby the tool can be easily and economically custom made for each debris removal job depending upon the amount of debris to be removed for a particular wellbore. FIG. 11 depicts a debris removal tool 500 with a length of coiled tubing 505 disposed within as a debris container. Rather than a permanent container like those depicted in FIGS. 1 & 2, the debris container in FIG. 11 is formed of coiled tubing that has been cut to length at the well surface and installed between the venturi portion 510 of the debris removal tool 500 and the filter 515 and one way valve 520 thereof.
In a preferred embodiment, a motor head 525 is inserted between the venturi portion and the coiled tubing thereabove, the motor head typically including connectors, double flapper check valves to prevent pressurized fluid from returning to the well surface and a hydraulic disconnect (not shown). The assembled apparatus can then be lowered into a wellbore to a predetermined depth proximate formation debris to be removed. The venturi apparatus is then operated, causing a suction and urging debris into the coiled tubing portion between the venturi 510 and the one way valve 520 .
FIG. 12 is a view of a debris removal tool 600 with a retrieval tool 610 disposed therebelow and a length of coiled tubing 615 disposed therebetween. Like the apparatus of FIG. 11, the coiled tubing 615 is used as a debris container and is measured and sized depending upon the amount of debris to be removed. In addition, a spoolable, double valve 620 is inserted in the coiled tubing string. The purpose of the spoolable, double valve is to facilitate the isolation of areas above and below the valve when debris and/or a downhole device is removed from a live well as described below. Because the double valve is spoolable, it can be wound on and off of a reel without being removed from a string of coiled tubing. In the preferred embodiment, the valves making up the double valve are ball valves. However, any type valve could be used so long as it is tolerant of stresses applied during reeling and unreeling with coiled tubing.
FIG. 13 is a section view showing a wellhead 700 with a blind ram 705 in a closed position and a lubricator 715 disposed thereabove with a retrieval tool 720 at the end of a coiled tubing string 725 disposed therein. The lubricator 715 is a pressure vessel which can be pressurized to the pressure of the wellbore and placed in fluid communication with the wellbore. At an upper end of the lubricator 715 , a stripper 730 allows coiled tubing to move in and out of the lubricator, maintaining a pressurized seal therewith. Valves 735 , 740 are provided at an upper end of the lubricator for pressurizing and bleeding pressure. FIG. 14 is a section view showing the wellhead 700 with the lubricator 715 attached thereto. The lubricator 715 is pressurized via valve 740 to wellbore pressure by an external source of pressure. In the preferred embodiment, the retrieval tool 720 within the lubricator 715 includes a meltable plug (not shown) disposed in the end thereof. The plug is made of a substance which, at ambient temperature is a solid that seals the interior of the tool to external pressure. The plug is designed to melt and disintegrate at temperatures found in the wellbore where the debris removal will take place.
FIG. 15 is a section view showing the wellbore opened and the retrieval tool lowered into the wellbore a predetermined distance. Double valve 620 , inserted in the string of coiled tubing 615 , is at a location within the lubricator 715 . FIG. 16 is a section view of the apparatus with a lower pipe ram 745 in the closed position and thereafter, the pressure in the lubricator bled off via valve 735 .
FIG. 17 is a section view of the wellhead 700 with the lubricator 715 and raised thereabove. The coiled tubing string 615 has been severed above the double valve 620 . FIG. 18 illustrates the assembly with the debris removal tool 510 and motor head 525 disposed within the lubricator 715 and an additional access port 750 and upper rain 755 added to the lubricator. FIG. 19 is a section view wherein the lubricator 715 , upper pipe ram 755 and access port 750 have been attached to the wellhead 700 with the lower pipe ram 745 closed. The lubricator 715 is pressurized via valve 740 to the pressure of the wellbore. FIG. 20 is a section view wherein the lower pipe ram 745 is open and the debris removal tool is lowered into the wellbore sufficient distance to place the retrieval tool therebelow in the area of the debris to be removed.
In the preferred embodiment, the retrieval tool is lowered into the well with a length of coiled tubing there behind sufficient and volume to house the debris which will be removed from the wellbore. After a sufficient amount of coiled tubing has been lowered into the well behind the retrieval tool, the venturi apparatus with its double safety valve is installed in the coiled tubing. As the retrieval tool reaches that location in the wellbore where it will be removed, the temperature present in the wellbore causes the plug in the end of the retrieval tool to melt by exposing the coiled tubing section to wellbore pressure and permitting communication between the venturi apparatus and the debris containing wellbore.
FIG. 21 depicts the wellhead assembly after the debris removal and device retrieval has been completed and the debris removal tool 510 has been raised out of the wellbore and is housed again in the lubricator 715 . Visible specifically in FIG. 21 is the double valve 620 , still in its opened position and raised to a location where it is accessible through the access port 750 . FIG. 22 is a section view depicting the upper pipe ram 755 between the access port 750 and the lubricator 715 in a closed position and the lower pipe ram 745 between the access port 750 and the wellhead 700 also in a closed position in order to isolate the access port 750 . As depicted in the figure, with the access port 750 isolated above and below, pressure is bled therefrom.
FIG. 23 is a section view depicting an access plate 751 removed from the access port 750 and the double valve 620 manipulated to a closed position. FIG. 24 is a section view of showing the pressure bled from the lubricator 715 via valve 735 . FIG. 25 depicts the lubricator 715 and access port 750 having been removed from the wellhead 700 , exposing the double valve 620 , the coiled tubing 615 thereabove having been severed.
FIG. 26 depicts the lubricator 715 with the debris removal tool 510 removed therefrom, leaving only a string of coiled tubing 615 in the lubricator 715 . As depicted in the figure, the coiled tubing string in the lubricator can now be reconnected to the coiled tubing string extending from the double valve 620 , which remains in the closed position. FIG. 27 is a section view depicting the lubricator 715 having been reconnected to the wellhead 700 and pressurized to wellbore pressure via valve 740 . Thereafter, the lower pipe ram 745 is opened and, as illustrated by the directional arrow, the coiled tubing string 615 is retracted from the wellbore.
FIG. 28 is a section view wherein the retrieval tool 610 and downhole device 611 has been lifted from the wellbore and is housed within the lubricator 715 . FIG. 29 is a section view wherein the blind ram 705 has been closed and, thereafter, the pressure within the lubricator 715 is bled via valve 735 . FIG. 30 is a section view wherein the lubricator 715 , the retrieval tool 610 and downhole device 611 have been removed from the wellhead 700 and the debris removal and tool retrieval procedure is completed, leaving the wellhead 700 with the blind ram 705 in the closed position.
As described in the forgoing, the invention solves problems associated with prior art sand removal tools and provides an efficient, flexible means of removing debris or retrieving a downhole device from a live or dead well. The design of the tool is so efficient that tests have demonstrated a suction created in the tool measured at 28″ of mercury, compared with a measure of as little as 3-5″ of mercury using a prior art device like the one shown in FIG. 1 .
While foregoing is directed to the preferred embodiment of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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A simple debris removal apparatus for use in a wellbore. In one aspect of the invention a modular, interchangeable venturi is provided which can be retrofit into an existing debris bailer having a filter and a debris collection container. In another aspect of the invention, a venturi is utilized to create a negative pressure in a wellbore sufficient to actuate a retrieval tool for a downhole device. In yet another aspect of the invention, a combination tool is provided which can evacuate debris in a wellbore, thereby uncovering a downhole device which can then be removed in a single trip. In yet another aspect of the invention, a debris removal apparatus is provided with a method for utilizing the apparatus in a wellbore on coiled tubing.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a 371 U.S. National Stage of International Application No. PCT/FR2013/051707, filed Jul. 16, 2013, which claims priority to French Patent Application No. 1256849, filed Jul. 16, 2012. The entire disclosures of the above applications are incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of photosolar conversion, and specifically to the optimisation of said conversion in order to improve the photoconversion yield of films or plates inserted between the solar radiation and a device such as an agricultural greenhouse, a phytoreactor or a photovoltaic cell. The invention relates specifically to the implementation of an interface doped with optically active components forming a light cascade. “Light cascade” in the sense of the present application is understood to refer to the wavelength transfer occurring by the association of a series of optically active components selected such that the re-emission wavelength of one type of component corresponds to the absorption wavelength of another type of component, each of the types of components being defined by a re-emission wavelength which is different from the absorption wavelength. Said components can be photoluminescent, scintillating, fluorescent, or laser-dye components.
[0003] The “light cascade” according to the present patent can also include one or more molecules producing an anti-Stokes shift (the atom of the molecule thus emits a photon with energy equal to the sum of the energy of the photon absorbed and of the phonon. The wavelength of the emitted photon is thus shorter). During the inelastic collision between a molecule and a photon, radiation with a shorter wavelength than that which enabled the excitation is emitted. The Stokes shift is the energy difference between the exciting wavelength and the wavelength of the emitted light, which is longer and thus has less energy. The molecule thus retains an energy surplus which can cause the emission of a longer wavelength than that received (with a second photon). A shift towards shorter wavelengths (thus with higher energy) than the incident light may appear. Such a shift is referred to as anti-Stokes.
BACKGROUND
[0004] French patent FR 2792460, which is known in the prior art, describes a photovoltaic generator comprising at least one photovoltaic cell and a transparent matrix deposited with at least one optically active material having an absorption wavelength lambda a and a re-emission wavelength lambda, the optically active material being selected such that lambda a corresponds to a range of lower sensitivity of the photovoltaic cell than lambda r , the matrix comprising a reflective coating. The matrix comprises, on the input surface, a dichroic filter substantially reflecting wavelengths of more than around 950 nm, and substantially transparent for wavelengths of less than 950 nm, and on the surface opposite the input surface a reflective coating for wavelengths of more than 400 nm, the photovoltaic cell being included in the transparent matrix.
[0005] U.S. Pat. No. 4,088,508, which is known in the prior art, describes an energy amplifying device that can be adapted to a solar cell, including a matrix with fluorescent substances dispersed therein.
[0006] U.S. Pat. No. 4,367,367 is also known, describing a collector suitable for concentrating solar energy on a photoelectric cell, including in combination at least one glass plate doped with a substance that is fluorescent when lit by sunlight. A photoelectric cell is attached to a lateral side of the plate, the other lateral sides of the plate being provided with a reflective coating. The cell is highly efficient in the fluorescent radiation wavelength range. A plurality of such glass plates can be stacked upon one another, each doped to absorb at a predetermined region of the spectrum and to fluoresce in a region in which a certain photoelectric cell is sensitive. A fluorescent dye in a suitable substrate can be applied as a surface layer on such glass plates, and this improves the overall efficiency of the collector.
[0007] U.S. Pat. No. 4,110,123 describes a photovoltaic cell, in which light is collected in a light concentrator including a transparent layer, the refraction coefficient of which is higher than that of the ambient medium and which contains fluorescent centres and is fed to a solar cell, characterised in that more than one concentrator/solar cell combination is stacked on top of another by means of a medium having a lower refraction coefficient than that of the concentrators, each concentrator being suitable for converting a portion of the incident spectrum into fluorescent light and for supplying same to a solar cell.
[0008] U.S. Pat. No. 7,541,537 describes a photovoltaic cell having improved conversion properties. The cell includes a cover for a photovoltaic device. In one embodiment, the cover includes a fluorescent material that shifts the wavelength of one portion of the incident light to be closer to the wavelength that produces the least amount of thermal loading on the photovoltaic device. In another embodiment, the cover comprises a fluorescent material between two reflective filters. The cell and the cover can be placed together in a stack or separated from one another.
[0009] The prior art solutions have problems of optical yield. When the matrix contains a plurality of dopants of various natures, the chemical or optical interactions thereof cause an attenuation or an alteration of the transmission in certain cases of high concentrations of dopants, or a loss of efficiency when the concentration of certain dopants is insufficient. An unsuitable concentration may even cause the extinction of certain re-emission phenomena, thus completely modifying the lighting spectrum produced by the doped interface. Furthermore, some of the prior art solutions propose a multi-layer interface formed by a stack of planes, each having a specific type of dopant. The disadvantage of said solutions is that the interactions take place in sequential fashion and do not enable the creation of enough interactions to have any real effect of optimising the lighting spectrum.
SUMMARY
[0010] In order to solve the disadvantages of the prior art, the invention relates, in the broadest sense thereof, to an optically active coating for improving the yield of photosolar conversion. Said coating is, by way of example, made up of a transparent matrix containing a plurality of optically active components absorbing light energy in a first absorption wavelength lambda A1 and re-emitting the energy in a second wavelength lambda R1 which is different from lambda A1 , said optically active components being selected such that the re-emission wavelength lambda R1 of at least one type of component corresponds to the absorption wavelength lambda A2 of at least one second type of component, characterised in that the C 2 /C 1 ratio of concentration C 1 of the optically active components of a first type in relation to the concentration C 2 of the optically active components of said second type is comprised between 0.4 and 0.6; C i designating the concentration in moles per litre of the component i in relation to the doped matrix.
[0011] The invention relates, in particular, to an optically active coating for improving photosolar yield such as to optimise the yield of a photovoltaic cell, characterised by comprising N types of OAC Stokes components, wherein the re-emission wavelength is shorter than the absorption wavelength, wherein N is equal to 3 or 5, the concentration C n of the level-N components being also comprised between 0.4N and 0.6N, the matrix also containing an OAC anti-Stokes component wherein the re-emission wavelength is shorter than the absorption wavelength. The highest type of level-N optically active component preferably has a re-emission wavelength with a peak of between 945 nanometres and 980 nanometres.
[0012] According to a first variant, said matrix is made up of a film of ethylene vinyl acetate or polymethyl methacrylate. According to a second variant, said matrix is made up of a methyl methacrylate resin or silicone. According to a third variant, said matrix is made up of a film of polyvinyl chloride. According to another variant, said matrix is made up of a film made up of a copolymer including 80% to 90% low-density polyethylene and 10% to 20% ethylene vinyl acetate. According to another variant, said matrix is made up of polyvinylidene fluoride.
[0013] The invention also relates to a photovoltaic module characterised by including at least one photovoltaic element associated with an optically active coating that is consistent with one of the aforementioned coatings. Said module advantageously also includes OAC anti-Stokes components wherein the re-emission wavelength, comprised between 550 and 800 nanometres, is shorter than the absorption wavelength, comprised between 1000 and 1500 nanometres. Advantageously, the module includes a reflecting rear surface, the photovoltaic element being encapsulated in an optically doped matrix such as to form said coating.
[0014] According to a specific variant, the module according to the invention includes a plurality of photovoltaic elements forming a matrix with an expansion of 0.25 to 0.75, the areas comprised between said photovoltaic elements being transparent. According to another variant, the matrix encapsulating the photovoltaic elements includes persistent compounds which make it possible to release light in the lack of solar exposure.
[0015] The invention also relates to optically active granules for the production of coatings, in particular to films in accordance with the invention, characterised by being made up of a transparent matrix containing a plurality of optically active components absorbing light energy in a first absorption wavelength lambda A1 and re-emitting the energy in a second wavelength lambda R1 which is longer than lambda A1 , said optically active components being selected such that the re-emission wavelength lambda R1 of at least one type of component corresponds to the absorption wavelength lambda A2 of at least one second type of component, characterised in that the C 2 /C 1 ratio of concentration C 1 of the optically active components of a first type in relation to the concentration C 2 of the optically active components of said second type is comprised between 0.1 and 0.2; C i designating the concentration in moles per litre of the component I in relation to the doped matrix. The granules are advantageously produced from doped polymers with high EVA content or polyvinyl chloride (PVC) or even from polyvinylidene fluoride.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The invention will be better understood from reading the following description, made in reference to the appended drawings, wherein:
[0017] FIG. 1 is a section view of a doped matrix according to the invention; and
[0018] FIG. 2 is a diagrammatic view of the incident and output spectrum of a doped material according to the invention.
DETAILED DESCRIPTION
[0019] FIG. 1 is a section view of a doped interface according to the invention. Said interface is made up of a transparent matrix containing optically active components with references A to D. In the described example of application, the interface is applied to the surface of a photovoltaic cell (2) of a known type. The matrix is made up of a rigid or flexible organic material, or else is in the form of a coating which can be applied in the form of a resin.
[0020] The organic material is selected, in particular, from:
[0021] polymethyl methacrylate (PMMA)
[0022] ethylene vinyl acetate (EVA)
[0023] polyvinyl chloride (PVC)
[0024] polycarbonate (PC)
[0025] methyl methacrylate (MMA)
[0026] low-density polyethylene (LDPE)
[0027] a methyl methacrylate resin or silicone
[0028] polyvinylidene fluoride (PVDF).
[0029] The optically active dopants are selected from:
[0030] organic luminophores (Stokes effect)
[0031] inorganic luminophores (anti-Stokes and persistent effect)
[0032] optically active molecules such as scintillating organic crystals with N+1, N+2, N+3, N+x anthracene φ rings,
[0033] perylene or derivatives, pentacene, or organic luminophores such as diphenyl, carbazol stilbene or derivatives, selected such that the emission spectra of some correspond to the absorption spectra of the other.
[0034] This has the purpose of producing the expected electromagnetic frequency shift from the UV and visible spectra to the near infrared in order to mobilise in the range of greatest sensitivity of the silicon photovoltaic cell, for example, the maximum light energy possible, the maximum photons of λ comprised between 620 and 990 nm corresponding to an energy near the gap of an n-p c.Si cell, for example. Perylene is a chemical compound of formula C 20 H 12 or C 32 H 16 , for example. This is an aromatic hydrocarbon presented as a brown solid.
[0035] Perylene emits blue or red fluorescence, and thus can be used as a blue or red dopant for organic LEDs, optionally substituted. It is also an organic photoconductor. It has maximum absorption at 434 nm with a molar extinction coefficient of 38,500 M-lcm-l at 435.75 nm, and has low solubility in water (1.2×10-5 mmol/l), like all the other polycyclic aromatic compounds.
[0036] All the carbon atoms of perylene are sp 2 hybridised, which explains why the central cycle is not shown as a fifth benzene ring (since then two carbon atoms would be sp hybridised and the molecule would lose a portion of the aromatic character and the fluorescent properties thereof). The structure of perylene has been intensively studied by X-ray diffractometry.
[0037] Pentacene is a chemical compound of formula C 22 H 14 belonging to the polycyclic aromatic hydrocarbon (PAH) family and formed by five benzene rings fused in line. The extended conjugated structure and the crystalline structure thereof mean that pentacene is a good p-type organic semiconductor (electron donor). It forms excitons therein by absorption of ultraviolet or visible radiation, making it highly sensitive to oxidation: this is the reason why, although it has the appearance of a red powder when it has just been synthesised, it gradually turns green when exposed to open air and light.
[0038] Pentacene is a promising material for the production of thin-film transistors and of organic field-effect transistors. The holes therein have a mobility of 5.5 cm2.V-1.s-1, which is close to the level of amorphous silicon. It forms p-n junctions with fullerene C60, which are used to manufacture organic photovoltaic cells.
[0039] For the component of the highest level N: 5,12-bis(phenylethynyl)naphthacene, also abbreviated as BPEN, is a polycyclic aromatic hydrocarbon of formula C 34 H 20 used as a fluorochrome for chemiluminescent tubes; it emits an orange light. This is an n-type organic semiconductor.
[0040] The aim of the system according to the invention is to mobilise, in a silicon solar cell, for example, which is mainly sensitive to light radiation comprised between 700 and 950 nm, an incident energy greater than that normally provided by solar light in said wavelength band. In principle, the solar energy used is defined by the overlap area of the emission spectrum of solar light and the absorption spectrum of the solar cell. Considering the specificity of the cell (absorption of energy photons corresponding to wavelengths of 700 to 950 nm) and given that the energy recovered by the solar cell is a function of solar irradiance—i.e. the number of photons transported—one of the means for increasing the yield of the cell is to make usable the photons of the portion of the solar spectrum located below 700 nm, from UV to the visible spectrum).
[0041] The used method transforms high-frequency photons (250 to 700 nm) into low-frequency photons (700 to 950 nm) using the fluorescent properties of certain chemical compounds taken as intermediaries in the transport of energy from sunlight. The substances are selected such that their absorption spectra constitute consecutive zones, making it possible to cover the entire solar spectrum in the area (250-700 nm) (overlapping frequencies or wavelengths). Light radiation with a predetermined wavelength λp can be absorbed by the substance in which the absorption spectrum includes said value of λ. The photons h v n or hc/λn which made it possible to excite the molecules of said substance (absorption phenomenon) are thus ultimately extracted from the incident beam. However, the unstable state which was conferred to the molecules has a very short duration. The return to the ground state (stable state of the molecules at a given temperature) can be carried out in part (statistical expression of the phenomenon) and, advantageously in the present case, by radiative emission (fluorescence/phosphorescence). The photons thus generated are found to correspond to the spectrum of absorption of another substance which will take over from same. It should be noted that a given substance can absorb either the emission of the substance that precedes same in the sequence of products used (transformed energy), or the portion of the emission of the solar spectrum that corresponds to same (non-transformed energy).
[0042] In the cell, the total usable energy can be expressed as:
[0000]
E
tot
=E
NT
+E
T
[0043] Wherein:
E NT : Non-transformed energy (700-800 nm zone of the solar spectrum) Σ ET : E of the transformation energies
[0000] Σ ET=E A1B1C1D E C1D +E D
[0046] Wherein:
A 1 B 1 C 1 and D: Substances in which the respective spectra share the solar spectrum in the rising direction of wavelengths E A1B1C1D : Energy which has gone through all the stages of transformation Ed: Energy from the transformation of radiation in the visible domain from the solar source located directly below the area of sensitivity of the solar cell via the single substance D.
[0050] The chemical compounds are trapped in a suitable matrix. The matrix should be applied to the cell such as to constitute a photon transformer which is inserted between the cell and the light source. The various types of chemical compounds are homogeneously dispersed in the matrix.
[0051] Since the emission of chemical intermediaries takes place in every direction, the emission of A (for example) is picked up by molecules B located either between A and the cell, or between A and the source (and so on). The low-frequency photons ultimately produced by time unit are directed half towards the cell and half in the opposite direction (the photons emitted in a plane parallel to the cell being negligible). The chemical substances used have high quantum efficiency of fluorescence (or phosphorescence) and should not result in photochemical processes that are likely to alter the nature (and thus the yield) of the photon transformer.
[0052] For example, the following table shows various examples of formulas and of the composition thereof and the concentration of optically active components in a PMMA plate with a thickness of three millimetres (in g/kg and in mole/litre):
[0000]
TABLE 1
Compounds
PPO
L V 850
L F R 305
2,5diphenyl
Uvitex OB
3G
Perylene
// OR 610
GG
Oxazole
2,5thiophene
Hostasol
Tetra. carboxy.
DiPerylene
Hostasol Red
Reference
C15H11NO
C26H26N2O2S
Naphthalimide
C24H8O2
C32H16
C23H12OS
Formula 1
0.44 g
0.11 g
0.06 g
1.52*10−3
1.95*10−4
1.35*10−5
mole/litre
mole/litre
mole/litre
Formula 2
0.44 g
0.11 g
0.06 g
0.006 g
1.52*10−3
1.95*10−4
1.31*10−4
9.28*10−6
mole/litre
mole/litre
mole/litre
mole/litre
Formula 3
0.22 g
0.11g
0.06 g
0.03 g
1.11*10−3
2.86*10−4
1.71*10−4
8.34*10−5
mole/litre
mole/litre
mole/litre
mole/litre
Formula 4
0.22 g
0.11 g
0.022395 g
1.32*10−3
3.40*10−4
8.0*10−5
mole/litre
mole/litre
mole/litre
Formula 5
0.22 g
0.11 g
0.03 g
1.11*10−3
2.86*10−4
8.34*10−5
mole/litre
mole/litre
mole/litre
[0053] The following table shows various examples of formulas and of the composition thereof and the concentration of optically active components in an EVA encapsulation film with a thickness of e=90 μm (in g/kg and in mole/litre):
[0000]
TABLE 2
Compounds
PRO
L V 850
L F R 305
2,5diphenyl
Uvitex OB
3G
Perylene
// OR 610
Oxazole
2,5thiophene
Hostasol
Tetra. carboxy.
diPerylene
RH800
Styryl 20
Reference
C15H11NO
C26H26N2O2S
Naphthalimide
C24H8O2
C32H16
C26H26N305
C33H37O3SCl
Formula 6
0.88 g
0.22 g
1.66*10−3
2.14*10−4
mole/litre
Mole/litre
Formula 7
0.31 g
0.16 g
0.03 g
1.32*10−3
3.49*10−4
7.04*10−5
mole/litre
mole/litre
mole/litre
Formula 8
0.88 g
0.22 g
0.025 g
0.00025 g
1.66*10−3
2.14*10−4
2.61*10−5
2.09*10−7
mole/litre
mole/litre
mole/litre
mole/litre
Formula 9
0.88 g
0.22 g
0.025 g
0.00025 g
1.66*10−3
2.14*10−4
2.61*10−5
1.75*10−7
mole/litre
mole/litre
mole/litre
mole/litre
[0054] In the examples shown above, the optically active granules with a diameter of 1 to 2 mm are made up of optically active molecules (OAMs) directly integrated into the various polymers such as PMMA, EVA, PVC and PE. Said granules can be used to produce coatings, films with light cascade movement (LC) for the various agricultural and photovoltaic applications. And yet, some of the materials degrade and lose their optoelectronic features, for example light cascades following the actions of photo-oxidation, hydrolysation and migrations of the OAMs. Said phenomenon appears in some of the polymer matrices such as the PE/EVA or EVA polyolefins used specifically for the production of agricultural films or the encapsulation of PV cells.
[0055] In order to reinforce the light fastness of the light cascade (LC) doped matrices, the OAMs are included in a medium that is compatible with same, such as PMMA, in which the OAMs/LC have constant optoelectronic characteristics. The LC-doped PMMA is micronised or powdered by a cryomilling technique and reduced to a size of several tens of micrometers in order to be used as a stable organic pigment containing all or part of the useful OAMs.
[0056] Said PMMA matrix is mixed into the EVA granules when extruding the film. The formula 2013E is then given as an example. The concentration rate of the powdered doped PMMA is 10%. The doped PMMA powder has a particle size of 2 micrometres and the concentration of dopants is of 5 g/Kg of LC PMMA premix. For 5 kg of OMMA-doped OMMA compound, 25 g of dopants distributed as follows:
[0057] PPO: 0.44, or 73.6% by weight of the doping formula
[0058] OB: 0.11, or 18.3% by weight of the doping formula
[0059] GG: 0.0479, or 8.1% by weight of the doping formula.
[0060] For the production of photovoltaic modules, the matrix located under the cells on the surface opposite the photon-collection surface, can advantageously be made of ethyl vinyl acetate, for example, encapsulating the photovoltaic elements (cells) and made reflective by inclusion of TiOx pigments. Likewise, the matrix located under the cells and encapsulating the photovoltaic elements can be made simultaneously reflective and persistent according to one embodiment, by the inclusion (doping) of persistent compounds such as Cu-doped ZnS inorganic crystals, for example, making it possible to release light under absolute darkness during a long time—more than one hour, for example—after interrupting the incident electromagnetic energy (light excitation). Likewise, the matrix located under the cells encapsulating the photovoltaic elements can also be made anti-Stokes by the inclusion of crystalline particles such as rare-earth oxysulphides Green UC2 from Riedel-de Haën or YF3YbEr from RP.
[0061] Moreover, the rear substrate (or backsheet) of the photovoltaic module can be made up of a polyfluorinated polymer such as polyvinylidene fluoride (PVDF) doped as the encapsulation matrix located under the cells with TiO2 and/or ZnS:Cu and/or Green UC2 rare-earth oxysulphide in order to grant same the additional functions of reflectance and/or persistence and/or anti-Stokes in wavelength bands that complement those of the encapsulation matrices of the Stokes light-cascade doped front surface. In addition, diffusing matrices increase the efficiency and the yield of the light cascades. Preferably, the light cascades are associated with diffusing loads, SiO 2 , SiO 3 , aluminosilicate zeolite, mesoporous silicon. It should be noted that EVA films are also interesting for the intrinsic diffusion coefficient thereof. Mesoporous materials have a contact surface of the order of 1000 m 2 /g/cm −1 and are good candidates for grafting optically active molecules (OAM)/light cascades (LC), the light fastness and the physical-chemical inertia thereof. The formulas RREFLEC 2010 A′, B′ and C′ in table 3 are part of this technique.
[0062] On the front surface, a LC with OAMs of fluorophores with persistence of less than 10 −8 seconds is provided, while on the rear surface, mixed LCs of OAMs and OACs (optically active crystals) with photoluminescence of more than than 10 −8 seconds are provided. Certain OACs can thus re-emit by reflection blue photons of 450 nanometres by photoluminescence after excitation.
[0063] The following is taken as an example of the joint use of two complementary light cascades: Formula 2013E on the front surface and formula RREFLEC 2010 B′ from table 3 on the rear surface. The efficiency of this film/encapsulation plate pair is even greater than the expansion of the photovoltaic cells (PV) in which, by module, the yield is lower than 0.9, since the former actually makes the entire surface of the module optoelectronically active, even the areas not covered with PV cells. In the LC-doped films/plates, the action of diffusing elements such as TiO2, SiO2, ultrafine or pyrogenated silicon, associated with the LCs is interesting in that they are transparent in the visible spectrum and take into account the photons re-emitted by the OAMs in 4Pi steradian in order to increase the useful path in the doped matrix.
[0064] In addition, the inorganic structure of the pyrogenated silicon in which the developed surface is of the order of 250 to 400 m 2 /g is a structure which is favourable for the grafting of OAMs and for the integration thereof. Thus, a photovoltaic module is obtained in which the optical characteristics of absorption, emission, reflection and persistence of the encapsulation materials that make up same complement one another and work together to improve the photoelectric gains of the cells and to improve the yields of the photovoltaic module.
[0065] C-Optically Active Rear Reflector
[0066] Doping of the EVA Film Under the Cells:
[0067] Optically active reflector in g/kg, thickness 450 μm of EVA and/or doping of the PVDF substrate (PolyVinylidene Fluoride backsheet).
[0000]
TABLE 3
Anti-Stokes
TtiO x < 0.6 μm
22205 ZnS
22330 ZnS
Oxisulphide IR
Diffusing
Lumilux
Persistent Exc.
Persistent Exc.
UC3 Lumilux exc.
Nanoparticlees
PPPO
OOB
white flow
UV em. 450 nm
UV em: 550 nm
1500 nm emi. 550 nm
Blc + SiO2 UF.
RREFLEC
00.75
00.375
2010 A
RREFLEC
00.75
00.375
11
22
2010 B
RREFLEC
00.75
00.375
22
2010 C
RREFLEC
00.75
00.375
22
22
2012
ARm/A
RREFLEC
00.75
00.375
22
22
2012
BRm/D
RREFLEC
1
0.5
2010 A′
RREFLEC
1
0.5
1
2010 B′
RREFLEC
1
0.5
1
2010 C′
[0068] For use in agricultural films, a stratification architecture with multiple layers is produced. The specialised optical treatments have complementary absorption and re-emission wavelengths from one layer to the other.
[0069] Thus, from a complete light cascade with 4 levels of rough UV or IR, the outer layer facing the sun is doped from UV to blue and the inner layer is doped to emit in the band from 600 to 700 nanometres. The outer layer is specifically dedicated to the first frequency shift, which also plays the role of UV protection.
[0070] Said technique is novel due to the technique of simultaneous coextrusion of films of different qualities by the same machine. It adapts to coextruded agricultural films made up of a 600-700 nanometre doped central ring which is additionally thermally treated or diffusing and the active outer layer of 400 to 500 nanometres which is additionally treated with antioxidants or hydrophobic. The choices of films are adapted to find conjugated or complementary optoelectronic effects which are favourable for the growth of plants and/or for the optical functions of pollinating insects.
[0071] The formulas below are adapted to the use of agricultural films for market garden plants, with a central ring and outer layer. The LC materials are made up of two specialised layers for growing tomatoes and cucumbers. The central ring is an 80-micrometer film, while the outer layer is of 60 micrometres. The film used is made of 4TT.
[0072] A complete series of formulas will be used to dope the 80 μm central ring of the film (formulas P012 to P0015), in said films the metering of the OB has been divided by 2 (formula P012) and by 4 (formula P013) in order to reduce or even eliminate the disrupting effects that doping has on pollinating insects. For the partial formulas, the central ring will be doped either with GG (formula P017) or with LRF3O5 (formula P018); the formula P016 is doping with a mixture of GG/LRF305.
[0000]
For market gardening (tomatoes, peppers) 80μ central ring
PPO
OB
2205
P22
GG
F305
OR610
P012 80μ
0.4
0.05
0.1
0.1
P013 80μ
0.4
0.025
0.1
0.1
P014 80μ
0.3
0.05
0.1
P015 80μ
0.3
0.05
0.1
P016 80μ
0.1
0.1
P017 80μ
0.1
P018 80μ
0.1
[0073] For the outer layer of the partially doped films, the dosing of the completely doped films for the PPO and the OB of formulas P0012 and P013 is used again, but with concentrations taken to values that correspond to films of 60 μm.
[0000]
For market gardening (tomatoes, peppers) 60 μm outer layer
PPO
OB
2205
P22
GG
F305
OR610
P019 60μ
0.533
0.066
P020 60μ
0.533
0.033
[0074] The rule of varying the concentration of OAMs is a function of the thickness of the films or plates of LC-doped materials. The notion developed herein is that of the active population of OAMs/OACs per unit of surface/per number of incident photons. The Beer-Lambert law applies here for adjusting the concentration of useful OAMs/OACs. This law is directly linked to the physical parameters; it is independent of the number of incident photons, which is another of the parameter of OPTO LC “smart” materials.
[0075] According to the Beer Lambert law:
[0000] D =log( I 0 /I )=Σ* c*d
Wherein: D: Optical density Σ: Molar extinction coefficient c: Molar concentration d: Path length I 0 : Light intensity at the input I: Light intensity at the output
[0083] Absorption Efficiency
[0000] Si( I 0 /I )=(100/10)(˜90% absorption→log(100/10)=log 10=1)
[0000] Si( I 0 /I )=(100/1)(˜99% absorption→log(100/1)=log 100=2)
[0000] D1=1=Σ c 1 d 1
[0000] D2=2=Σ c 2 d 2
Only depending on the substance at a given wavelength=Cst, from which in order to pass from 10% to 1% it suffices to have (c 1 d 1 )/(c 2 d 2 )=2
[0085] Either, for example, to double the concentration for a constant thickness or to double the thickness with a constant concentration.
[0086] If the coefficient Σ is uniform throughout the spectral domain (200 nm-700 nm), the concentration must be around 2*10 −3 moles/litre. Said conditions are ideal for a given substance in the following case:
[0087] Diluted solution
[0088] 99% absorption (absorption efficiency)
[0089] A diluted solution must have good conditions in order for the absorption thereof not to be disrupted by molecular associations.
[0090] When there are n substances to be mixed: it is necessary to multiply d by n (thickness of the matrix) in order to have an ideal concentration.
[0091] For example:
[0000] n=4
[0000] d= 4*0.1
[0000] d=0.4
[0092] The other concentration rule to be highlighted is that of the relative number of OAM1/OAM2/OAM3/OAM4/OAM n-1 in relation to one another. Said concentration varies from one molecule to another in accordance with the molecular weight thereof. To repeat the model of the initial sequence of the benzene PAH OAMs, the concentrations thereof vary from 10-3, 10-4, 10-5, etc. In accordance with the molecular weight of each OAM, or with the number of aromatic rings thereof: anthracene 3 phi (10-3), naphthacene 4 phi (10-4), pentacene 5 phi (10-5), etc.
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The invention relates to optically active coatings for improving the yield of photosolar conversion, consisting of a transparent matrix containing a plurality of optically active constituents absorbing the light energy in a first absorption wavelength lambdaA1 and reemitting the energy in a second wavelength lambdaR1 different from lambdaA1, said optically active constituents being selected such that the reemission wavelength lamdaR1 of at least one type of constituent corresponds to the absorption wavelength lambda A2 of at least one second type of constituent, characterised in that the C 2 /C 1 ratio of concentration C 1 of the optically active constituents of a first type in relation to the concentration C 2 of the optically active constituents of said second type is between 0.13 and 0.26; C i designating the concentration in moles per litre of the constituent i in relation to the doped matrix.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is filed concurrently with applications LPHA 21,357 and LPHA 21,358 of the same inventor, which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to light-transmissive viewing screens, and in particular to lenticular screens having light-absorbing material disposed in grooves between the lenticules of the screen.
2. Description of the Prior Art
Light-transmissive viewing screens such as rear projection screens are commonly provided with integral lenticules or lens elements. These lens elements are shaped to collect image-forming light rays projected onto the rear side of the screen by one or more projection tubes, and to concentrate the rays to form a bright image at the peaks of lens elements on the front or viewing side of the screen.
It is well known that providing a coating of masking material in grooves between the light-emitting lens elements, to absorb ambient light, enhances image contrast. Examples of lenticular screens with such masking material are described in commonly-owned U.S. Pat. No. 4,605,283 to Douglas A. Stanton, which is hereby incorporated by reference. The Stanton patent recognizes the desirability of minimizing contact of the masking material with the screen surfaces defining the grooves. The masking material not only absorbs ambient light incident to the masked grooves at the viewing side of the screen, but also partially absorbs the image-forming light entering the lens elements from the rear of the screen, thereby attenuating the image-forming light eventually reaching the light-emitting peaks of the lens elements. This attenuation occurs wherever the masking material contacts the surface of a lens element, thereby locally increasing the critical angle for total internal reflection (TIR) of light rays striking the rear of the lens elements. As is explained in the Stanton patent, this increase of the critical angle decreases the range of angles from which image-forming light rays received at the rear of the screen will be totally reflected toward the light-emitting peaks of the respective lens elements. To minimize the total area of each lens element contacted by the masking material, thus minimizing the total surface area of the screen for which the TIR is reduced, the Stanton patent proposes that the masking material be provided in the form of a multiplicity of small light-absorbing particles. Each particle makes minimal contact (e.g. point contact) with the outer surface of the lens element against which it is disposed, and the particles are contained within each groove by a layer extending between respective sidewalls of the lens elements which define the groove.
Selective deposition of the light-absorbing masking particles into the grooves of a lenticular screen such as that disclosed in the Stanton patent can be achieved by reasonably simple methods. Any particles which land on the rounded peaks of the disclosed lens elements can be wiped or jarred off and tend to drop into the grooves. However, selective deposition is more difficult with screens having peaks with concave central portions, such as are described in U.S. Pat. No. 4,573,764 to Ralph H. Bradley, which is hereby incorporated by reference. With such screens it has been found difficult to keep the deposited particles out of the concave portions of the peaks. It has also been found difficult to achieve uniform filling of the grooves with the particles. Both of these objectives must be achieved in order to ensure high brightness and high contrast of images formed on the screen.
Another problem experienced is associated with retaining the particles in the grooves without damaging the screen. In the Stanton screen masking arrangement, the layer containing the particles in each groove is preferably formed by heating the face of the screen until the uppermost particles in each groove fuse together. There is only a small margin of error between applying sufficient heat energy to fuse the uppermost particles into a layer and overheating the screen material (typically a plastic material such as polymethyl methacrylate) and causing optical distortion of the lenticules.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a lenticular, light-transmissive screen having a multiplicity of light-absorbing particles securely affixed in grooves between the lenticules of the screen, with minimum contact to the screen.
It is another object of the invention to provide a simple but effective method for selectively applying light-absorbing masking particles to the grooves of a light-transmissive, lenticular screen.
It is a further object of the invention to provide such a method which both minimizes the deposition of the particles on the light-emitting peaks and which effects uniform coating of the groove areas to be masked.
It is yet another object of the invention to securely affix the particles to the screen while both minimizing contact of the particles with the screen and preventing excessive heating of the screen.
In accordance with the invention, these and other objects are achieved by filling the grooves to a predetermined depth with particles having a substantially higher microwave absorption coefficient than the screen material and having heat-fusible outer surfaces. The particles are then affixed in the grooves without overheating the screen by transfusing the screen and the particles with microwave radiation of sufficient energy to fuse the particles to each other and to points of contact with the lenticule sidewalls. Because of its substantially lower absorption coefficient, the screen is not heated sufficiently to cause any distortion.
In a preferred embodiment of the invention, the particles are selectively provided in the grooves by applying a slurry comprising a mixture of a volatile liquid and the light-absorbing particles. The surface of the screen is wiped to effect uniform filling of the grooves while removing slurry from the peaks of the lenticules. This is more easily achieved than wiping off bare particles, because the wetted particles have less friction and tend to flow across the screen in front of the wiping implement carrying away particles which are on or near the peaks, even if the peaks are concave. After wiping, the volatile liquid quickly evaporates, leaving only the particles. Any particles which remain on the peaks after the application of microwave radiation can be readily removed by another wiping step, because they tend to be isolated and because they tend to fuse to the screen over only relatively small areas of contact. Conversely, each particle in a groove is generally secured by several points of contact with other particles and, if adjacent thereto, by a point of contact with the screen.
BRIEF DESCRIPTION OF THE DRAWING
The invention will now be described with reference to exemplary drawing figures, of which:
FIG. 1 illustrates the spreading of a slurry containing light-absorbing particles across the surface of a lenticular screen, shown in cross-section;
FIG. 2 illustrates the screen with the slurry deposited in the grooves between the lenticules; and
FIG. 3 illustrates heating of the slurry in the grooves by microwave radiation.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a preferred method for filing the grooves between lenticule peaks 10 of a screen 12 with a viscous slurry 14 containing light-absorbing particles. In accordance with this method, the viscous slurry is deposited at one end of the screen, and is spread across the screen by a doctor blade 16 having inner edges configured to contact the peaks of the lenticules and the screen edges on opposite sides of the screen. In this figure, only the right-hand portion of the screen 12 (shown in cross-section) and the right-hand portion of the doctor blade 16 are shown. Horizontal edge 18 of the blade contacts the lenticule peaks, and right-hand vertical edge 20 of the blade contacts the right-hand edge 22 of the screen. Preferably, at least the horizontal edge 18 of the blade is made from a material such as a plastic which will not scratch the lenticule peaks of the screen.
The manner in which the slurry is spread across the screen to fill the grooves can best be understood by referring to FIGS. 1 and 2 together, which respectively depict the operation of the doctor blade 16 and the resulting coverage of the screen with the slurry 14. At the instant depicted by FIG. 1, the doctor blade 16 is moving toward the viewer and approaching the near end of the screen 12. The level 24 of the slurry pushed along in front of the blade has fallen substantially from its initial level, when it was deposited at the far end of the screen. The blade serves to both evenly fill the grooves 26 of the screen and to wipe the peaks so that substantially none of the particles in the slurry remain on the peaks. The horizontal blade edge 18 may be straight, as shown, or may be contoured to match the lenticule peaks which, in the exemplary screen disclosed, have longitudinally-extending, concave indentations. Such contouring will reduce the likelihood that light-absorbing particles will remain on the peaks after the blade has passed by, but is generally not necessary in view of the tendency of most particles in the indentations to flow along in front of the blade.
The blade edge 18 may also be contoured to protrude slightly into each groove 26, to establish a predetermined depth of the slurry in the grooves. This depth will be determined by the desired depth of the light-absorbing masking particles in the grooves, which in turn is determined by the optical design criteria for each particular screen.
The slurry itself is produced by mixing light-absorbing particles with a volatile liquid in proportions which produce the desired viscosity. The viscosity should be sufficiently high to prevent the slurry from draining out of the grooves and to minimize the amount of volatile liquid which must be evaporated, but it should be sufficiently low to ensure wetting of the particles, thereby minimizing their frictional contact with the screen surface. Volatile liquids which are especially suitable are alcohols, and in particular isopropyl alcohol.
With respect to the light-absorbing particles used in the slurry, a wide range of suitable sizes and compositions is available, as is described in the above-mentioned U.S. Pat. No. 4,605,283 to Stanton. Especially suitable for slurry deposition into the grooves of a typical lenticular screen having peak-to-peak spacing of approximately 300 microns and having concave indentations in the lenticule peaks with a radius of curvature of approximately 50 microns are relatively-large particles, such as 75 micron diameter particles available from 3M Company of St. Paul, Minn. under part no. 50814-55. These particles have the requisite high light absorbency, high microwave absorption coefficient, and surface fusibility when the particles are heated by exposure to microwave radiation. Their diameter is also sufficient to facilitate removal from the lenticule peaks by the horizontal blade edge 18 and to minimize the number of places where they contact the sidewalls of the lenticules.
After deposition of the particles in the grooves, the screen is moved to an affixing station as is illustrated in FIG. 3. At this station, the screen and the particles in the grooves are transfused with microwave radiation of sufficient energy to fuse the particles to each other and to the screen, without optically distorting the lenticules. The energy expended will depend on the size of the screen, the particle diameters, the amount of non-evaporated liquid remaining in the slurry, and the relative arrangement of the microwave source and the screen.
During this step, the particles will tend to settle in their respective grooves as the liquid in the slurry evaporates, and the initial level of the slurry left in the grooves must be high enough to compensate for such settling, to achieve the desired depth of the particles affixed in the grooves. After completion of this microwave heating step, the lenticule peaks may once again be wiped by a blade to remove any particles remaining on the peaks.
In a test of the microwave heating step, conducted before discovery and testing of the slurry deposition technique, particles were deposited in the grooves of a 4.0 centimeter by 3.7 centimeter screen by simply dropping the particles onto the screen and wiping off any particles landing on the peaks, as is disclosed in the Stanton patent. Particles had a diameter of about 75 microns and were obtained from 3M Company under part no. 50814-55. The deposited particles were optimally heated to fusion in a NORELCO Model 7100 microwave oven which was operated at 650 watts of microwave output power for four minutes. When heated for less than three minutes there was insufficient fusion of the particles to securely affix them in the grooves. When heated for over four minutes the particles tended to lose their spherical shape and made contact with substantial areas of the lenticule sidewalls, thereby adversely affecting TIR.
Although the invention has been described with reference to a particular embodiment, numerous variations can be made without departing from the scope of the invention, as is set forth in the appended claims. For example, other types of particles which have a substantially higher microwave absorption coefficient than the screen material could be used. Examples are plastic-coated metal particles, plastic-coated metal-cored particles other than toner particles, and black-dyed polyvinyl-chloride plastic particles. Polyvinyl-chloride, unlike many other plastics, readily absorbs microwave radiation. Also, a much less viscous slurry may be utilized by, for example, containing the screen in a walled enclosure having a height approximately equal to the height of the lenticule peaks. Such a low-viscosity slurry might be useful in situations where particles otherwise tend to stick to the lenticule peaks of a screen.
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Light-absorbing particles are selectively applied to a lenticular light-transmissive screen, such as a projection television screen. The particles are selectively deposited in grooves between lenticules of the screen by filling the grooves to a predetermined depth with a slurry comprising a mixture of a volatile liquid and the light-absorbing particles. Microwave radiation is applied to the screen with the deposited particles, to effect evaporation of any unevaporated liquid and fusing of the particles to each other and to the screen.
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This application claims the priority of U.S. Provisional Application No. 61/118,058, filed Nov. 26, 2008.
BACKGROUND OF THE INVENTION
The invention relates to suspended ceiling structures and, in particular, to electrification of such ceiling structures.
PRIOR ART
Commercial building spaces such as offices, laboratories, light manufacturing facilities, health facilities, meeting and banquet hall facilities, educational facilities, common areas in hotels, apartments, retirement homes, retail stores, restaurants and the like are commonly constructed with suspended ceilings. These suspended ceiling installations are ubiquitous, owing to their many recognized benefits. Such ceilings ordinarily comprise a rectangular open grid suspended by wire from a superstructure and tile or panels carried by the grid and enclosing the open spaces between the grid elements. The most common form of grid elements has an inverted T-shaped cross-section. The T-shape often includes a hollow bulb at the top of the inverted stem of the T-shape. A popular variant of this standard T-shape includes a downwardly open C-shaped channel formed by the lower part of the inverted tee.
Advances in electronics has fed further advances and led the world into the digital age. This digital movement creates an ever-increasing demand for low voltage direct current (DC) electrical power. This demand would seem to be at least as great in finished commercial space as any other occupied environment. A conventional suspended ceiling has potential to be an ideal structure for distributing low voltage electrical power in finished spaced. Many relatively low power devices are now supported on such ceilings and newer electronic devices and appliances are continuously being developed and adopted for mounting on ceilings.
The ceiling structure, of course, typically overlies the entire floor space of an occupiable area. This allows the ceiling to support electronic devices where they are needed in the occupied space. Buildings are becoming more intelligent in energy management of space conditioning, lighting, noise control, security, and other applications. The appliances that provide these features, including sensors, actuators, transducers, speakers, cameras, and recorders, in general, all utilize low voltage DC power.
As the use of electronics grows, the consumption of low voltage electrical power likewise grows. This seemingly ever accelerating appetite for DC power presents opportunities for more efficient transformation of relatively high voltage utility power typically found at 110/115 or 220/240 alternating current (AC) volts with which the typical enclosed space is provided. Individual power supplies located at the site of or integrated in an electronic device, the most frequent arrangements today, are often quite inefficient in transforming the relatively high voltage AC utility power to a lower DC voltage required by an electronic device. Typically, they can consume appreciable electric power in a standby mode when the associated electronic device is shut off. It is envisioned that a single DC power source serving the electronic needs of a building or a single floor of a building can be designed to be inherently more efficient since its cost is distributed over all of the devices it serves and because it can take advantage of load averaging strategies.
SUMMARY OF THE INVENTION
The invention permits and augments the practical and versatile use of the grid elements of a conventional style suspended ceiling to supply and distribute low voltage electrical power to the area of a building with which it is associated. In accordance with the invention, a grid runner or tee of generally conventional cross-sectional shape is employed as a rigid carrier for one or more pair of conductors or as a conductor or conductors itself.
As disclosed, the conductors can be conductive inks, metal foils, metal tapes, metal wires, or the components of a grid tee or combinations of these elements. A conductor, where it is distinct from the structure of a tee itself, can be located along various surfaces of a tee either in symmetrical or non-symmetrical relation to a central vertical plane of symmetry of the tee. In numerous disclosed embodiments, a conductor can be economically formed in situ as an ink trace deposited on the structure of a tee. This ink trace can be formed before or after a tee is roll-formed into a finished shape from a sheet metal strip. Similarly, a conductive foil, tape, or wire can be fixed onto the strip stock or formed tee.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a conventional grid tee;
FIG. 2 is a cross-sectional view of a conventional modified form of grid tee;
FIG. 3 is a cross-sectional view of a novel modified form of grid tee useful in providing an electrified grid according to the invention;
FIGS. 4A-4E are grid tee cross-sections with discrete electrical conductors symmetrically arranged on opposite sides of a central vertical plane;
FIGS. 5A-5D are cross-sectional views of grid tees having pairs of conductors asymmetrically arranged with respect to the mid-plane of a respective grid tee;
FIGS. 6A-6C are cross-sectional views of grid tees having parts of their bodies separated by an electrical insulator to form separate conductive circuit paths without additional conductors;
FIG. 7 is a cross-sectional view of a grid tee 30 having a multiplicity of conductors;
FIG. 8 is a fragmentary isometric view of a grid tee and separately formed insulator cap and wire assembly;
FIG. 9 is cross-sectional view of a grid tee fitted with an assembly of conductive and non-conductive layers;
FIG. 10 is a view similar to FIG. 3 including a diagrammatic showing of a connector assembly;
FIG. 11 is a fragmentary isometric view of a grid tee similar to that shown in FIG. 6C ;
FIG. 12 is a cross-sectional view of a grid tee with a conductive path within the web or stem of the tee;
FIG. 13 is a diagrammatic representation of a cross-section of a grid tee having conductive ink traces and a clip used to establish a connection to feed or draw power from such traces;
FIG. 14 illustrates a grid tee with conductors running vertically on a grid tee;
FIG. 15 is a fragmentary isometric view of a grid tee 10 having multiple easily tapped conductors;
FIG. 16 illustrates a grid tee with a flange over-cap carrying conductive traces; and
FIG. 17 illustrates a grid tee made of electrically insulating material.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 4A , discrete electrical conductors 11 , 12 are fixed to the upper sides of a flange 13 of a grid runner or tee 10 of conventional cross-section. The numeral designation 10 will be used throughout the following disclosure when reference is made to a grid tee of standard configuration. As is customary, the structural body or mass of the tee 10 is roll-formed from metal sheet stock, typically steel. The tee cross-section includes an upper hollow reinforcing bulb 14 and a separate cap 16 folded at its edges over flange elements diverging from a double layer stem 18 extending up to the bulb 14 , as is customary. The separate strips forming the tee proper and the cap can be prepainted or coated with a protective film before they are rolled to their finished shape. The conductors 11 , 12 in this and other embodiments can take various forms including strips of conductive ink, metal foil, or tape of copper, brass, or aluminum, for example, or single or multi-strand wire running longitudinally with the length of the tee. The conductors 11 , 12 are fixed to underlying areas of the tee with a suitable adhesive which may serve as an electrical insulator and prevent electrical contact between the conductor 12 , 13 and tee 10 . Alternatively, a separate electrically insulating medium may be applied to either the tee 10 or conductor 11 , 12 , apart from the adhesive medium therebetween. It is contemplated that the protective coating applied to the sheet material of the tee can serve as the requisite insulator. Still further, the exposed surfaces of the conductors 11 , 12 , i.e. those surfaces not facing the upper side of the flange 13 or other tee parts in other embodiments, can be covered with suitable insulating material to resist short circuiting against metal objects when a tee is installed in a ceiling structure. As depicted in FIGS. 4A-4E , the conductors 11 , 12 can be situated in numerous locations. In FIGS. 4C-4E , the grid cross-section or profile is of the conventional downwardly open C-shaped channel type. In FIGS. 4C and 4E , the conductors are permanently placed in the hollow of the bottom channel against respective flat interior surfaces of the tee. In these latter figures, the tee is designated by the numeral 20 .
Unless indicated differently, it will be understood that a conductor that is separate from a tee 10 , 20 , will be adhesively secured to the tee, or otherwise permanently affixed thereto, and will be electrically isolated therefrom.
As shown in FIGS. 5A-5D , the conductors 11 , 12 can be arranged in asymmetrical patterns, when viewed along the longitudinal direction of a grid tee. Such arrangements can be used, for example, to assure proper assembly of grid elements and electrical connectors.
It is contemplated that any of the arrangements of FIG. 4 or FIG. 5 can be modified by eliminating one of the pair of conductors 11 , 12 , and by using the body of the tee 10 or 20 as the second conductor. Most commonly, the grid tees 10 or 20 will be formed of sheet steel, however, aluminum may be used and such aluminum may be extruded if not roll-formed. In the case of the two-piece tee 10 , either the main body (that is, the upper flange elements 17 , double layer stem 18 , and bulb 14 ) or the cap 16 , can constitute the conductor individually or collectively. Where an electrical connection is to be made to the tee 10 or 20 directly, the protective paint or coating applied to it will be locally omitted or removed to expose a conductive area. Where convenient or necessary, a brass or copper terminal can be attached to the conductive exposed area of the tee 10 , 20 .
With reference to FIG. 6A , the grid tee cap 16 is isolated from a main body 15 of the tee 10 by insulating material 26 thereby allowing the cap to afford one conductive path or conductor and the main body 15 to provide the other conductive path or conductor. In FIG. 6B , the main body 15 is bisected by insulating material 26 so that the left and right sides of this tee element provide separate conductive paths or conductors.
Regarding the arrangement of FIG. 6A , either the body 15 or the cap 16 or both can be provided with a conductive trace of conductive ink, metal foil, or metal tape or wire. Such conductor can be electrically insulated from the respective body or cap element or can be in electrical contact with it to complement its current capacity.
It will be understood that suitable terminals, connectors, and the like will be attached to the various described grid tees conductor elements where lengths of grid tees are joined, and/or intersect and/or are tapped for power at a local electronic device, or are fed from a power supply.
It will be further understood that insulator layers can be coated or otherwise formed in situ or can be laminated to the respective tee element from roll stock, for example. Suitable insulating material is well known in the electrical arts. The conductive ink, in addition to using suitable metals, can employ electrically conductive non-metals including carbon.
The grid tee 30 illustrated in FIG. 7 can be formed of rolled metal sheets and, in the illustrated case is without an upper reinforcing bulb. Alternatively, the tee 30 can be extruded of aluminum in one piece. The conductors 31 can be permanently affixed to a dielectric or insulator sheet 32 which is laminated or otherwise bonded to the stem of the tee 30 . The conductors 31 can be copper or brass traces, each of adequate cross-sections to carry the expected currents independently of each other. A separate upper cap 33 can be made as an extrusion of suitable dielectric material such as polyvinylchloride which is extruded or molded around a conductor in the form of a wire 34 . The conductor or wire 34 can serve as a common ground or source for the individual conductors 31 . As discussed above, the conductors 31 can be fixed to the sheet stock forming the tee 30 before the stock is roll formed into the illustrated tee shape.
Referring to FIG. 8 , a grid tee 40 has the general shape of the previously disclosed tee 20 . An upper cap 41 is fixed on a reinforcing bulb 14 of the tee 40 . The cap can be an extruded thermoplastic such as PVC or other electrical insulator. The upper cap contains a wire set 42 , 43 providing electrification of the grid tee 40 . The cap 41 can be mechanically attached to the bulb 14 of the grid tee 40 by inserting prongs 44 integrally molded on the cap into receiving apertures 46 and retained therein by a friction fit or an interference fit provided by a barb-like configuration in the prongs. It will be understood that the cap 41 or an equivalent can be provided with a single wire where the conductivity of the grid tee 40 , itself, is utilized or can be provided with a multiplicity of wires.
In FIG. 9 , there is shown a grid tee having an elongated plastic bar 48 secured to the bulb 14 such as by a pressure sensitive adhesive. Typically, the bar is applied after the grid tee 10 is formed. As an alternative to adhesive fixing of the bar 48 to the tee 10 , the bar, as shown, can have a channel or C-shaped cross-section with legs fitting over the bulb 14 . On an upper surface of the bar 48 can be coated a conductive ink 49 to provide a conductor. If desired, an insulating layer 51 can be applied to the ink layer 49 and, in turn, a second ink layer 52 can be applied to the upper side of the insulating layer 51 . The reduced width of the upper conductive layer 52 and the underlying insulating layer 51 provides accessibility to the lower conductive layer 49 for suitably formed connectors for supplying or utilizing electrical power. The plastic bar 48 along with the various conductive and insulating layers 49 , 51 , 52 , can be applied to the tee 10 in the factory after the tee is rolled or otherwise fabricated or can be applied in the field before or after the grid is installed.
FIG. 10 illustrates an elongated insert assembly 56 proportioned to snap into the novel grid tee 57 shown in FIG. 3 . The insert 56 which runs the full length of the tee 57 includes an insulating channel 58 including a web and legs. Permanently attached to the opposed legs are associated opposed conductors 62 . The conductors 62 can comprise any of the foregoing described conductor compositions. The legs are proportioned to be frictionally held or mechanically captured within the interior of the depending channel formed by the flange of the tee 57 . More particularly, hems 63 formed by folded-in edges of the sheet stock forming the tee 57 underlie the distal edges of the legs so as to mechanically capture the insert 56 within the tee channel. A connector block 55 , preferably molded of a suitable plastic is proportioned to snap into the lower channel or slot of the tee 57 . The block 55 includes a pair of opposite rounded projections 60 sized to fit in the channel and be retained therein by the hems 63 . Spring-like metal blade contacts 59 engage respective conductors 62 to transfer power to or from the conductors. Leads 61 connect the blade contacts 59 to external electric devices which can be integrated with or supported by the block 55 .
In FIG. 11 , a tee 65 analogous to the tee 20 is split at its mid-plane with the left and right sides being isolated from one another by insulating material 26 . One or both halves of the tee 65 can be provided with conductors 66 . The conductors 66 can be electrically connected to their respective tee halves or can be electrically insulated from such associated halves. Where no separate conductor 66 is provided, the tee half can provide a conductive path for electrical power.
Referring now to FIG. 12 , a tee 10 can be provided with a conductor in the form of a printed ink trace 71 or a conductive foil, tape, or bar. The conductor 71 can be applied to one of the layers 18 of the web with an insulator layer between it and each of the web layers. Typically, this can be done while the strip forming the tee 10 is flat. The sheet area forming the interior of the tee is first coated with an insulating layer, then the conductor layer such as the referenced conductive ink, and then an overcoat insulator layer. One or both of the stem or web layers 18 can be perforated during the tee forming process to provide access to the conductor 71 .
With reference to FIG. 13 , two conductive ink traces 76 are formed over electrically insulated areas of the bulb 14 of a tee 20 . A plastic electrically insulating clip 77 maintains electrical contacts 78 against the pair of traces 76 . The contacts 78 have wire leads 79 adapted to feed power to the traces 76 or to draw power from the same.
Referring to FIG. 14 , a tee 10 has one or more conductors 81 running vertically from the top of the bulb 14 to the lower flange 13 . The conductors 81 can, for example, be printed with conductive ink over suitable insulating layers. In appropriate circumstances, the flange 13 can be provided with apertures 82 through which the conductors 81 may be accessed from the lower face of the flange 13 .
FIG. 15 illustrates a tee 10 on which a plurality of conductors 86 are printed or otherwise established on the upper side of the flange 13 . The conductors 86 are isolated from one another and are isolated from the flange by an insulating layer applied to the top surface of the flange 13 . Additionally, the conductors 86 are over-coated with an insulating layer to avoid short circuiting. The over-coating of the top insulating layer may be omitted at points 87 to facilitate connection with electrical contacts or electrical wires.
Making reference to FIG. 16 , a conventional grid tee 10 can be fitted with a cap 91 after the grid tee is installed. The cap can be made of plastic or metal suitably coated with an insulating layer on its interior. The cap 91 is printed with a conductive ink to form one or more conductors. The conductors 92 are over-coated with an insulating material to prevent shorting against surfaces or edges of the tee 10 . Alternatively, the cap 91 can be structured such that when it is installed, the conductor or conductors are spaced away from the lower surface of the flange 13 or cap 16 . By temporarily removing the cap 91 , the conductors 92 are readily accessible for establishing a circuit with a connector for supplying or drawing power.
FIG. 17 illustrates a novel grid tee 96 which is extruded or otherwise formed of electrically insulating material such as PVC or other well-known thermoplastic or thermosetting material. Conductors 97 are attached to any of those surface locations as previously described and preferably on non-visible surfaces of the tee 96 . Since the tee 96 is electrically insulating, there is no requirement that the conductors be insulated from the tee and can be directly attached to the same by any suitable expedient such as adhesive or mechanical interlocking.
The foregoing tee constructions and electrification of the same can deliver power to various devices carried over, in or under the plane of a ceiling. Such devices while drawing power from the grid electrification, can communicate to other nearby or remote devices with radiofrequency signaling.
While the invention has been shown and described with respect to particular embodiments thereof, this is for the purpose of illustration rather than limitation, and other variations and modifications of the specific embodiments herein shown and described will be apparent to those skilled in the art all within the intended spirit and scope of the invention. Accordingly, the patent is not to be limited in scope and effect to the specific embodiments herein shown and described nor in any other way that is inconsistent with the extent to which the progress in the art has been advanced by the invention.
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An elongated grid tee for supplying low voltage power on a suspended ceiling comprising at least two electrically conductive paths electrically insulated from each other, extending lengthwise of the tee, and accessible for receiving or supplying electrical power at numerous locations along the length of the tee.
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BACKGROUND
1. Field
The present disclosure relates to intracellular delivery, and relates in particular to compositions for intracellular delivery of therapeutic agents, diagnostic agents, and other materials in the presence or absence of targeting groups. The present disclosure is directed, inter alia, to polymer compositions comprising linear PNAI, cyclic PNAI, linear PEI, and/or cyclic PEI, useful for delivering compounds or substances into a cell. The present disclosure is also directed, inter alia, to methods of using compositions comprising cyclic PNAI and/or cyclic PEI.
2. Description of Related Art
Cells are the basic structural and functional units of all living organisms. All cells contain cytoplasm surrounded by a plasma, or cell, membrane. Most bacterial and plant cells are enclosed in an outer rigid or semi-rigid cell wall. The cells contain DNA which may be arranged in 1) a nuclear membrane or 2) free in cells lacking a nucleus. While the cell membrane is known to contain naturally occurring ion channels, compounds that are therapeutically advantageous to cells are usually too large to pass through the naturally occurring ion channels. Conventional interventional methods for delivering compounds or substances into cells have proved difficult in view of the need for the compounds to pass through the cell membrane, cell wall, and/or nuclear membrane.
Molecular biology has resulted in mapping the genomes of many plants and animals, including the mapping of much of the human genome. The potential for advances in the understanding of the genetic basis of diseases is great, as is the potential for the development of therapies to treat such diseases. To fully take advantage of these advancements and treatment therapies, however, methods are needed for delivering desired compounds into the target cells. Accordingly, researchers developed a variety of intracellular delivery methods for inserting genes and other compounds into both plant and animal cells.
For example, calcium phosphate DNA precipitation has been used to deliver genetic material into cells in cell culture. However, one drawback of this method is that the transfection efficiency (the percentage of transfected cells in a given population) and subsequent gene expression is generally very low.
Improved transfection has been achieved using viral vectors (e.g., adenovirus and retrovirus), but again, difficulties with gene expression have persisted. In addition, substantial concerns regarding antigenicity and the potential of mutant viruses and other possible deleterious effects exist. For example, some viruses may integrate into the genome and facilitate stable expression. If the virus integrates in a way that disrupts normal cell function, however, adverse consequences could result (e.g., cell death, transformation, cancer, etc.).
Liposomes, manufactured more easily than viral vectors, have shown promise as gene delivery agents. Liposomes have fewer biological concerns (for example, they are generally non-antigenic) but the efficiency of transfection and gene expression using liposomes has typically been lower than with viruses.
Gene guns, or biolistic delivery systems, use heavy metal particles (e.g., gold) coated with DNA to fire the particles at high speed into cells. While gene guns have enabled gene expression in culture systems, they have not worked well in vivo. Furthermore, the blast of heavy metal particles may cause damage to the cells and may also introduce undesirable foreign materials, e.g. gold particle fragments, into the cells.
Electroporation is another method of delivering genes into cells. In this technique, pulses of electrical energy are applied to cells to temporarily create pores or openings in the cell to facilitate entry of DNA. Electroporation may damage cells, though, and has not been shown to be highly effective in vivo.
Gene therapy has been heralded as the next revolution in modern medicine, being seen as a potential cure to many diseases both inherited and acquired. Gene therapy is the delivery of genetic information, typically plasmid DNA contained in a vector, to a cell. Typically, the DNA enters the cell via endocytosis and is released into the cytoplasm. Ultimately, the DNA interacts with the host cell environment to (for example) produce proteins encoded by the DNA. One major area of study for gene therapy is the correction of inherited diseases in which a genetic disorder stemming from a malfunctioning endogenous gene may be attenuated by a “healthy” exogenous gene. As a result of extensive genomic research, the genetic makeup of many diseases and their healthy counterparts have been deduced (e.g., cystic fibrosis, Huntington's disease, Alzheimer's disease, and sickle cell anemia), which has spurred on further gene transfer research. The primary obstacle still standing in the way of successful treatment is delivery; it must be cell specific, the gene transfer must be efficient, and the vector must be non-toxic (Putnam, D. “Polymers for Gene Delivery Across Length Scales” Nature Materials Vol. 5 June 2006: 439-451).
The first and most developed area of gene transfer research has utilized viral vectors to introduce DNA. This area has produced some positive results, though the vector itself is inherently flawed. Viruses have evolved the ability to use the host cell's own replication machinery to efficiently and rapidly replicate their own genetic information, which often results in the death of the host cell. To get around this problem, viruses used for transfection are genetically modified to be replication defective. This requires the removal of its virulent genetic information and the insertion of a therapeutic gene. The initial results from early clinical trials using this technique were positive, but early success was soon diminished when three cases of leukemia-like complications were detected in participants of a clinical trial (Wong, S. Y., J. M. Pelet, D. Putnam. “Polymer systems for gene delivery—Past, Present, and Future” Progress in Polymer Science Vol. 32 April. 2007: 99-837). The virus's random transgenic insertion of its genetic payload into the host cell chromosome was to blame, since it could potentially insert into an area that coded for a protein responsible for the regulation of cell growth and division. Other potentially lethal complications that may occur using a viral vector include initiation of an immunological response by the host, as well as the potential for the vector to travel to disease-free tissue.
The clarification and correction of these complications has become a major area of interest in this field. At the same time many have turned to non-viral delivery systems to find a safer method of gene delivery, including delivery of naked DNA by physical methods, lipid based vectors, and synthetic polymer vectors (Taira, K., K. Kataoka, T. Niidome. Non - viral Gent therapy: Gene Design and Delivery . Tokyo, New York Springer Science & Business Media, 2005). Delivery of free plasmid DNA via electoporation into a cell has been an enticing approach, given the absence of an immune response that is more evident in molecular vector systems. Electroporated DNA is induced to enter a cell by an application of electric or magnetic fields to the targeted tissue, which increases the permeability of cell membranes. Although this is one of the most precise methods to target a certain tissue, it is not cell specific and requires high levels of unencapsulated DNA, which has been shown to lead to high blood pressure and slow heart rates (Taira, K, 2005). An alternative method is to form hydrophobic lipoplexes, liposomes that associate with DNA, which are more readily taken up through interactions with the cell's phospholipid bilayer. Combined with the addition of a ligand or signaling sequence, these vectors can be more efficient at entering targeted cells.
Payload as well as transfection efficiency have been shown to increase when lipid based delivery is used in conjunction with cationic polymers (Wong, S. Y., 2007). Charged polymers, such as polyethylenimine (PEI), have been incorporated into vector systems called polyplexes, which have become popular because of their ability to be manipulated in the laboratory to achieve desired characteristics; however some obstacles still stand in the way. A current challenge in the design of cationic vectors is overcoming cytotoxicity. A number of researchers have studied the effects of adding further modifications to enhance biocompatibility. The exact mechanism that causes cytotoxicity is not entirely certain, but the leading hypothesis is that ionic interactions between the cationic moieties of the vector and the anionic domains on the cell surface lead to polyplex aggregation on the outer plasma membrane (Wong, S. Y., 2007). The cytotoxic effect has been shown to be caused and exacerbated by several physical properties including molecular weight (MW), degree of branching, charge density, cationic functionality type, three dimensional conformation, as well as polyplex size, surface area and flexibility (Wong, S. Y., 2007). Of the different properties that increase toxicity, MW has been shown to be one of the leading parameters. This has posed a crucial dilemma, since increasing the MW within a certain limit is also beneficial to transfection efficiency (Wong, S. Y., 2007). Other problems that arise when using cationic vectors include introducing DNA into non-target cells, and the systemic stability of the polyplex in the blood stream.
The present disclosure provides new and/or better methods for delivering compounds, including genetic material, into a cell. The methods of the present disclosure provide a significant advantage over prior art methodology in that enhanced levels of intracellular delivery and—in the case of nucleotides—gene expression may be achieved. In addition, the methods of the present disclosure may be performed in cell lines which may be otherwise resistant to intracellular delivery and gene expression using other conventional means. These and/or other aspects of the present disclosure will become apparent from the further discussions herein.
BRIEF SUMMARY
The present disclosure provides polymer compositions useful for delivering compounds into a cell. More particularly, the polymer compositions comprise cyclic PNAI and/or cyclic PEI.
The present disclosure also provides methods of delivering at least one compound or substance (including, without limitation, nucleic acids and/or small-molecule pharmaceuticals) into a cell comprising administering to the cell a composition comprising said at least one compound to be delivered and a cyclic PNAI, a cyclic PEI, or combinations thereof.
In addition, the present disclosure provides methods of treating a patient comprising administering to said patient a composition comprising a therapeutically effective amount of a compound and a cyclic PNAI, a cyclic PEI, or combinations thereof.
The subject disclosure provides methods of effecting the expression of at least one nucleotide sequence in a cell comprising administering to said cell a composition which comprises a said at least one nucleotide sequence and a cyclic PNAI, a cyclic PEI, or combinations thereof.
If desired, the compositions may further comprise a carrier.
Also included in the present disclosure are compositions and kits comprising, for example, a therapeutically effective or diagnostically effective amount of a compound to be delivered, a cyclic PNAI and/or a cyclic PEI and/or a carrier, and, in the case of a kit, optionally other conventional kit components.
These, as well as other, aspects of the invention are set forth in greater detail below.
The present disclosure provides a compound selected from the group consisting of:
and combinations thereof, wherein n is an integer from 1 to 750. In one aspect, n is an integer from 1 to 500. In one aspect, n is an integer from 1 to 250. In one aspect, n is an integer from 1 to 200. In one aspect, n is an integer from 1 to 150. In one aspect, n is an integer from 1 to 120. In one aspect, n is an integer from 10 to 120. In one aspect, n is an integer from 10 to 100. In one aspect, n is an integer from 25 to 75. In one aspect, said compound corresponds to Formula 7. In one aspect, said compound corresponds to Formula 8. In one aspect, said compound corresponds to Formula 9. In one aspect, said compound corresponds to Formula 10. In one aspect, said compound corresponds to a combination of Formulae 7, 8, 9, and 10.
The present disclosure provides a method of producing a linear PNAI, the method comprising: combining propargyl toluene-4-sulfonate with 2-ethyl-2-oxazoline; and adding sodium azide to said combination, thereby producing said linear PNAI.
The present disclosure provides a method of producing a cyclic PNAI, the method comprising: precipitating the linear PNAI described above; and adding said precipitated linear PNAI to a Cu(I)Br/PMDETA/CHCl 2 solution, thereby producing cyclic PNAI.
The present disclosure provides a method of producing a linear PEI, the method comprising: precipitating the linear PNAI described above; and performing acid reflux of said cyclic PNAI, thereby producing a linear PEI.
The present disclosure provides a method of producing a cyclic PEI, the method comprising: producing a cyclic PNAI as provided above; and performing acid reflux of said cyclic PNAI, thereby producing a cyclic PEI.
The present disclosure provides a method of introducing a substance into a cell, the method comprising: mixing said substance with: linear PNAI; cyclic PNAI; linear PEI; cyclic PEI; or a combination thereof, and exposing said cell to said mixture, thereby introducing said substance into said cell. In one aspect, the substance is a nucleic acid sequence. In one aspect, the introducing of a nucleic acid sequence effects the expression of a protein encoded by said nucleic acid sequence. In one aspect, the introducing of a nucleic acid sequence suppresses the expression of a protein. In one aspect, the substance is a drug. In one aspect, the cell is a prokaryotic cell. In one aspect, the cell is a eukaryotic cell. In one aspect, the cell is an animal cell. In one aspect, the cell is a mammalian cell. In one aspect, the cell is a yeast cell, a bacterial cell, or a plant cell.
The present disclosure provides a method of producing cyclic PNAI, the method comprising: combining a compound of the formula R—X with 2-ethyl-2-oxazoline; adding a nucleophile to said combination to produce linear PNAI; precipitating linear PNAI; and adding said linear PNAI to a solution comprising Cu(I)Br and PMDETA, thereby producing cyclic PNAI. In an aspect of this embodiment, R may be selected from Formula 1 or Formula 2, below. In an aspect of this embodiment, X may be selected from Formula 3 (below), Formula 4 (below), Br − , or I − . In an aspect of this embodiment, the nucleophile may be selected from NaN 3 and NaSH.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the nature, objects, and advantages of the present disclosure, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements.
FIG. 1 shows Scheme 1, the synthesis of PNAI utilizing different end groups. A strong nucleophile is used to terminate the reaction.
FIG. 2 shows Scheme 2, the synthesis of cyclic PNAI from an alkyne initiated and N 3 terminated PNAI polymer utilizing the Cu(I)-catalyzed 2+3 cycloaddition click reaction.
FIG. 3 shows Scheme 3, the synthesis of linear and cyclic PEI.
FIG. 4 shows: 4 A) 1 N NMR of linear PNAI; 4 B) 1 H NMR of cyclic PNAI; 4 C) 13 C NMR of linear PNAI; and 4 D) 13 C NMR of cyclic PNAI.
FIG. 5 is a representative example showing gel permeation chromatography (GPC) of linear and cyclic PNAI. The shift to a longer retention time for the cyclic PNAI is indicative of the change to a smaller hydrodynamic radius.
FIG. 6 is a representative example showing MALDI of: 6 A) linear PNAI; and 6 B) cyclic PNAI. For linear PNAI, predominately the loss of N 2 is observed in reflector mode. Once cyclized, the triazole ring negates the loss of N 2 .
FIG. 7 shows the results of infrared (IR) spectroscopy of linear (lower trace) and cyclic (upper trace) PNAI. The absence of the azide resonance at 2100 cm −1 (box) in the cyclic polymer gives evidence of the cyclization.
FIG. 8 is a representative example showing gel permeation chromatography (GPC) results of linear (dashed arrows, pointing to left-most trace for each of 8 A through 8 D) and cyclic (solid arrows, pointing to right-most trace of each of 8 A through 8 D) of different molecular weight PNAI.
FIG. 9 shows 1 H NMR of: 9 A) linear PNAI; 9 B) cyclic PNAI; 9 C) linear PEI; and 9 D) cyclic PEI.
FIG. 10 shows results of IR spectroscopy of: 10 A) linear PNAI; 10 B) cyclic PNAI; 10 C) linear PEI; and 10 D) cyclic PEI. The absence of the azide resonance at 2100 cm −1 in the cyclic polymers gives evidence of the cyclization.
FIG. 11 is a representative example showing MALDI of: 11 A) linear PEI; and 11 B) cyclic PEI derived from the linear and cyclic PNAI shown in FIG. 8A . One may predict the expected molecular weight of linear and cyclic PEI from the molecular weight of the linear and cyclic PNAI from which it was synthesized. For linear PEI, predominately the loss of N 2 is observed in reflector mode. Once cyclized, the triazole ring negates the loss of N 2 . The expected molecular weight of the hydrolyzed polymer suggests no degradation has occurred during the acid hydrolysis and no evidence is seen of the cyclic ring opening.
FIG. 12 shows initial comparative gene transfection study between linear and cyclic PEI of three different molecular weights, as measured by the number of cells in one field exhibiting fluorescence. A significant difference was observed between linear and cyclic PEI.
DETAILED DESCRIPTION
Before the subject disclosure is further described, it is to be understood that the disclosure is not limited to the particular embodiments of the disclosure described below, as variations of the particular embodiments may be made and still fall within the scope of the appended claims. It is also to be understood that the terminology employed is for the purpose of describing particular embodiments, and is not intended to be limiting. Instead, the scope of the present disclosure will be established by the appended claims.
In this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural reference unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure belongs.
In the past two decades, ligand-conjugated polymer based (polyplex) gene delivery has been utilized with increasing efficiency. Polymer vectors have gained much attention from the gene delivery and pharmaceutical community because their physiochemical properties are well understood, and they can be modified in the laboratory. The ability to change a vector's physical makeup—e.g., by altering its side chain composition, polydispersity, and molecular weight to increase payload efficiency and decrease cytotoxicity—has become a main focus of interest in this field. Construction of polymer vector libraries which contain polymers that vary slightly in their composition is an empirical method to categorize and test for desired properties. The present disclosure provides methods for polymerization of 2-ethyl-2-oxazoline to form poly(N-acylethylenimine) (PNAI) with functional azide and alkyne terminal end groups that are covalently bonded using a “click” chemistry intramolecular reaction to synthesize cyclic architectures. The present disclosure also provides uses for the same. The subsequent hydrolysis of the side chains provides a new architecture of poly(ethyleneimine) (PEI) for gene delivery.
To form a polyplex, cationic monomers are polymerized into long chains which are capable of encapsulating naked DNA by electrostatic interactions arising from DNA's negatively charged phosphodiester backbone. The polymer first condenses DNA to a size that is sufficient for cellular uptake, which is dependent on its nitrogen to phosphate charge ratio (Wong, S. Y., 2007). This also determines how well the cationic polymer will associate with the vector. Enroot to the target cell, the vector must not lose its cargo but once it reaches a desired location within the cell the DNA must dissociate. Upon reaching a cell, entry can be accomplished by several methods mediated by cellular endocytosis. Vectors equipped with specific internalizing sequences or ligands can be used in a cell specific manner to internalize them. Non-specific methods include ionic interactions with proteoglycans bound to cell membranes to stimulate endocytosis or the inclusion of lipophilic residues capable of interacting with the cell membrane as described earlier. Here again, polyplex size is crucial to cellular uptake with optimal sizes differing between various cells. Once internalized, the vector must continue to protect the cargo from degradation; a major threat of this comes from lysosomes. Clathrin mediated endocytosis, which directs shuttling through the endo-lysosomal pathway, has been one pathway studied for internalizing polyplexes (Wong, S. Y., 2007). The exact mechanism for lysosomal escape has not been fully elucidated. However, some researchers have inferred that by incorporating amine groups into the polymer, it becomes capable of absorbing protons in the low pH environment of the endo-lysosome; this may cause the organelle to burst due to osmotic pressure releasing the endocytosed material into the cytosol. Once in the cytosol, endogenous cytosolic factors are commonly incorporated to move either the polyplex or the naked DNA to the nucleus where nuclear localizing signals can then be used to gain entry (Wong, S. Y., 2007). Finally, vector dissociation and gene expression must occur for gene transfer to be successful.
Several polymers have been studied for the task of encapsulating and delivering DNA. Some of those most extensively used include PEI, poly-L-lysine, cationic dendrimers, and arginine-rich proteins (Taira, K., 2005). They all share a common characteristic in that they possess an amine functional group which is used to condense the DNA. PEI has become one of most studied polymer vector systems and has paved the way for much of what we know about cationic vectors. Commercially available PEI is synthesized through a one step ring opening polymerization of aziridine, which produces a highly branched molecule (Ham, G. E. “Polymeric Amines and Ammonium Salts”; Goethals, E. J., Ed., Pergamon Press; Elmsford, N.Y., 1980; p. 1), whose excessive random branching has been shown to increase cytotoxicity while at the same time elevate DNA binding efficiency (Feijen, J., Z. Zhong. “Low molecular weight linear polyethylenimine-b-poly(ethylene glycol)-b-polyethylenimine triblock copolymers: synthesis, characterization, and in vitro gene transfer properties” Biomacromolecules, 2005: 6, 3440-3448; Jeong, J. H., S. H. Song, D. W. Lim, H. Lee, T. G. Park. “DNA Transfection using Linear Poly(ethylenimine) Prepared by Controlled Acid Hydrolysis of Poly(2-ethyl-2-oxazoline)” Journal of Controlled Release, 2001: 73, 391-399; Fischer, D.; Li, Y.; Ahlemeyer B.; Krieglstein J.; Kissel, T.; Biomaterials. 2003, 24, 1121-1131; Lv, H.; Zhang, S.; Wang, B.; Cui, S.; Yan, J.; J. Control Release. 2006, 114, 100-109; Wightman, L.; Kircheis, R.; Rossler, V.; Carotta, S.; Ruzicka, R.; Kursa, M.; et al. J. Gene Med., 2001, 3, 362-372; and Petersen, H.; Kunath, K.; Martin, A.; Stolnik, S.; Roberts, C. J.; Davies, M., Kissel, T. Biomacromolecules, 2002, 3, 923-936). It is clear that PEI's buffering capabilities play an important role in transfection, yet the exact mechanism is not fully elucidated and further research in this area is needed (Brissault, B., K. Antoine, G. Christine, L. Christian, D. Olivier, C. Herve. “Synthesis of linear polyethylenimine drivatives for DNA transfection” Bioconjugate Chemistry , (2003): 14, 581-587). What is evident is that PNAI has a well defined degree of polymerization, low polydispersity, relatively simple preparation and high versatility depending on the initiator and terminator used during polymerization which has made it highly coveted within the fields of medicine, materials science and technology (Aoi, K., M. Okada. “Polymerization of Oxazolines” Polymer Science, 1996: 151-208; and Einzmann, M., W. Binder. “Novel Functional Initiators for Oxazoline Polymerization” Journal of Polymer Science Part A: Polymer Chemistry , May 2001: 2821-2831). Previous investigations into vector design demonstrates that neither highly branched nor pure linear polymers work efficiently as polyplexes indicating that the most optimal architecture most likely lies in-between the two extremes (Tang, M. X., C. T. Redemann, F. C. Szoka. “In Vitro Gene Delivery by Degraded Polyamidoamine Dendrimers” Bioconjugate Chemistry Vol. 7 November 1996: 703-714; Feijen, J., 2005; and Jeong, J. H., 2001). It has also been shown that molecular weight affects the efficiency of PEI (Godbey, W. T., Wu, K. K., Mikos, A. G. “Size Matters: Molecular Weight Affects the Efficiency of Poly(ethylenimine) as a Gene Delivery Vehicle” Journal of Biomedical Materials Research Vol. 451999: 268-275). This has led many in the field to realize that systematic studies of polymer architecture must be undertaken by developing well characterized synthetic routes which yield readily reproducible products. A novel approach to synthesizing complex but well defined architecture is to first polymerize 2-ethyl-2-oxazoline to form linear poly(N-acethylenimine) (PNAI) with terminal ends that can be further processed into various architectures. Then, through acid hydrolysis of PNAI's side chains, it is possible to obtain PEI of new and potentially therapeutic designs.
The polymerization chemistry of 2-substituted oxazolines shows wide versatility depending on the nature of monomers, initiators, and terminating agents (Kobayashi, S; Tokuzawa, T; Saegusa, T; Macromolecules 1982, 15, 707-710; Kirlabil, H; Yagci, Y; Turk J Chem, 2004, 38, 477-485; and Einzmann, M., 2001). Oxazolines are heterocyclic imino ether compounds, 2-oxazolines being five membered hererocyclic imino ether compounds or imidates. The general polymerization reaction of 2-oxazolines follows a living mechanism leading to well-defined polymerizations and low polydispersities (Aoi, K., 1996). Oxazoline polymers are amenable to a range of applications in both medicine and materials due to their low toxicity (LD 50 <4 g/kg) and high hydrophilicity (Wong, S. Y., 2007). Oxazolines are also used in materials science as nonionic polymer surfactants, and polymer networks (including hydrogels) (Aoi, K., 1996).
2-oxazolines are polymerized via a cationic ring-opening polymerization to produce the corresponding derivatives of poly(N-acylethylenimine) (PNAI) (Aoi, K., 1996). The polymerization of cyclic imino ethers is thermodynamically favored due to the favorable isomerization of the imino ether group to the amide functionality and elimination of monomer ring strain. The cationic ring-opening polymerization of 2-oxazolines can follow either ionic or covalent mechanisms depending on the initiator utilized. Ionic initiators include Brønsted and Lewis acids, carbocations, trialkyl amonium salts, triflates, and alkyl halides while weak nucleophiles are covalent initiators. Termination occurs following the addition of a strong nucleophile or adventitious reactions with water. This versatility in initiation and termination allows for the introduction of different functionalities at either end of the polymer chain.
Cyclic polymers are a class of polymer architectures whose properties have not been vastly studied but are believed to exhibit unique topology and physical properties (Semlyen, J. A. Cyclic Polymers, 2 nd ed.; Kluwer Academic: Dondrecht, The Netherlands, 2000). This can be attributed to the technical difficulties in preparing and purifying well-defined cyclic polymers (Laurent, B. A.; Grayson, S. M. J. Am. Chem. Soc. 2006, 128, 4238-4239; and Eugene, D. M.; Grayson, S. M.; Macromolecules, 2008, 41, 5082-5084). Typically, methods reported for the cyclization of linear polymer precursors suffer from poor yields and competing reactions (Hadjichritidis, N.; Pitsikalis, M.; Pispas, S.; Iatrou, H.; Chem. Rem, 2001, 101, 3747). Recently, a method preparing well defined cyclic poly(styrene) synthesized by atom transfer radical polymerization (ATRP) utilizing the Cu(I)-catalyzed 2+3 cycloaddition reaction between an azide and an alkyne has been reported (Laurent, B. A., 2006). Since the publication of this paper, many other types of cyclic polymers have been reported, including cyclic block copolymers (Eugene, D. M., 2008).
The utilization of highly efficient “click reactions”, as termed by Sharpless et al. (Kolb, H. C.; Finn, M. G.; Sharpless, K. B. Angew. Chemie, Int. Ed. 2001, 40, 2004) has been widespread due to their high specificity, near-quantitative yields, and near-perfect fidelity in the presence of most functional groups (Matyjaszewski, K.; Gao, H.; Macromolecules. 2006. 39, 4960-4965). The Cu(I)-catalyzed [3+2] cycloaddition reaction between an azide and an alkyne has been the most utilized of the click reactions because it is fast, high-yielding, functional group tolerant, and compatible with a range of solvents. To utilize this type of chemistry for the synthesis of a cyclic PEI polymer, we are studying the synthesis of polymers of 2-oxazolines with both an alkyne and an azide as end groups.
Inspection of the molecular architecture and synthesis is the next important step in the development of a polymer vector system, with cyclic PNAI being a molecule never before investigated. Prior analysis of cyclic architecture has revealed that they have unique topologies and physical properties (Semlyen, J. A., 2000); however more research is needed to understand how they will behave as polyplexes. There are several reasons why cyclic architecture may be of an optimal therapeutic design for delivering a genetic payload. In comparison to the linear form, cyclic architecture has been shown to have longer systemic circulation times and to accumulate in higher concentrations within tissues (Nasongkla, N., B. Chen, N. Macaraeg, M. E. Fox, J. M. J. Frechet and F. C. Szoka. “Dependence of Pharmacokinetics and Biodistribution on Polymer Architecture: Effect of Cyclic versus Linear Polymers” Journal of the American Chemical Society March 2009: 3842-3843). Also their circular shape is analogous to that of plasmid DNA which may help to better encapsulate the genetic payload. In addition the cyclized form of the polymer physically takes on a smaller hydrodynamic volume that may lead to better packing and transfection ability; this will hopefully be analyzed soon by pore diffusion studies. Other biological applications could be to functionalize the side chains of cyclic PNAI to form molecules capable of carrying various drugs intracellularly.
Experimental Pathway
It has been reported that initiators containing trifluoromethanesulfonic acid esters (triflates) and p-toluenesulfonic acid esters (tosylates) give good results with respect to polydispersity and controlled molecular weight resulting in the preparation of defined telechelic polymers (Einzmann, M., 2001). The synthesis of PNAI has been studied using different initiators to have specific end groups on the polymer ( FIG. 1 ). To synthesize a polymer with a terminal methyl group, methyl tosylate was used as an initiator, although the present disclosure also encompasses other initiators such as trifluoromethanesulfonate (triflate), I − , and Br − . For the synthesis of a cyclic PNAI, initiation can be used to introduce a terminal alkyne. To accomplish this, propargyl toluene-4-sulfonate (C 10 H 10 O 3 S, propargyl p-toluenesulfonate) was obtained from Sigma-Aldrich (cat. no. 09954) and used as an initiator (see, e.g., FIG. 1 , “R-OTs”) with polyethyloxazoline(2-ethyl-2-oxazoline). The methyl tosylate (methyl p-toluenesulfonate) and propargyl toluene-4-sulfonate as initiators resulted in reproducible polymers with low polydispersities. Termination is achieved by the addition of a strong nucleophile (Scheme 1), such as NaN 3 . This termination enables introduction of an azide to the PNAI either with direct addition of NaN 3 . This reaction scheme is detailed further in EXAMPLES 1 and 2, below.
In reaction scheme 1, of FIG. 1 , “R” may be selected from the following formulae:
In reaction scheme 1, FIG. 1 , “X” may be selected from I − , Br − , and the following formulae:
The “Nucleophile” of FIG. 1 could be sodium azide (NaN 3 ) or sodium hydrosulfide (NaSH). As shown in FIG. 2 , using sodium azide as the nucleophile produces the coupling link shown below as Formula 5. Using sodium hydrosulfide would produce a coupling link shown as Formula 6.
The cyclization ( FIG. 2 ) of the PNAI containing alkyne and azide end groups was next preformed. PNAI was dissolved in 100 mL of DMF and in a separate flask, N,N,N′,N′,N-Pentamethyldiethylenetriamine (PMDETA), was dissolved in 120 mL DMF. The two solutions were degassed three times by freeze pump thaw cycles. The CuBr was added to the flask containing PMDETA and DMF while frozen. Once the two solutions were thawed, the PNAI solution was added slowly with a syringe pump at 2 mL/hr until all the solution was added. This reaction scheme is detailed in EXAMPLE 3, below.
Once the cyclic PNAI was obtained, acid hydrolysis was used to synthesize cyclic PEI (Scheme 3; FIG. 3 ; EXAMPLE 5, below). In addition, linear PEI was synthesized with the linear analog of PNAI used to produce the cyclic PEI as a linear comparison. (Scheme 3; FIG. 3 ; EXAMPLE 4, below).
The variable “n” shown in FIGS. 1-3 may be an integer from about 1 to about 750, from about 1 to about 625, from about 1 to about 500, from about 1 to about 450, from about 1 to about 400, from about 1 to about 350, from about 1 to about 300, from about 1 to about 250, from about 1 to about 200, from about 1 to about 150, from about 1 to about 120, from about 1 to about 100, from about 1 to about 75, from about 1 to about 50, from about 1 to about 25, from about 1 to about 10, from about 1 to about 5, from about 10 to about 500, from about 10 to about 400, from about 10 to about 300, from about 10 to about 200, from about 10 to about 150, from about 10 to about 120, from about 10 to about 100, from about 10 to about 95, from about 10 to about 80, from about 10 to about 75, from about 10 to about 70, from about 10 to about 65, from about 10 to about 60, from about 10 to about 55, from about 10 to about 50, from about 10 to about 45, from about 10 to about 40, from about 10 to about 35, from about 10 to about 30, from about 10 to about 25, from about 10 to about 20, from about 25 to about 500, from about 25 to about 400, from about 25 to about 300, from about 25 to about 200, from about 25 to about 150, from about 25 to about 120, from about 25 to about 250, from about 25 to about 95, from about 25 to about 80, from about 25 to about 75, from about 25 to about 70, from about 25 to about 65, from about 25 to about 60, from about 25 to about 55, from about 25 to about 50, from about 25 to about 45, from about 25 to about 40, from about 25 to about 35, from about 25 to about 30, from about 100 to about 500, from about 150 to about 500, from about 200 to about 500, from about 250 to about 500, from about 300 to about 500, from about 350 to about 500, from about 400 to about 500, from about 450 to about 500, and preferably from about 25 to about 75.
Materials
N,N,N′,N′,N-Pentamethyldiethylenetriamine (PMDETA) and copper (I) bromide were used as purchased from Sigma-Aldrich (St. Louis, Mo.). Ethyl ether anhydrous and methylene chloride (CHCl 2 ) were used as purchased from Fisher Scientific (Fair Lawn, N.J.). Propargyl toluene-4-sulfonate was purchased from Fluka, stirred with CaCO 3 , filtered, and placed over molecular sieves. Acetonitrile was purchased from Fisher Scientific, distilled over calcium hydride, and placed over molecular sieves. 2-ethyl-oxazoline purchased from Aldrich, distilled over calcium hydride, and placed over molecular sieves.
Instrumentation
Mass spectral data was acquired using a Bruker Autoflex III matrix-assisted laser desorption time of flight mass spectrometer (MALDI) with delayed extraction using the reflector and positive ion mode. MALDI-TOF MS samples of PNAI were prepared by the combination of PNAI (2 mg/mL) in THF, 1,8,9-Anthracenetriol (20 mg/mL) in chloroform, and KTFA (2 mg/mL) in THF at a ratio of 1:1:0.3. MALDI-TOF MS samples of PEI were prepared by the combination of PEI (10 mg/mL) in methanol and 1,8,9-Anthracenetriol (20 mg/mL) in chloroform with no additional counterion at a ratio of 0.2-0.5:1. M n and PDI for all polymers were calculated using PolyTools software. Size exclusion chromatography (GPC) was carried out on a Waters model 1515 series pump (Milford, Mass.) with three-column series from Polymer Laboratories, Inc. consisting of PLgel 5 μm Mixed C (300 mm×7.5 mm) and PLgel 5 μm 500 Å (300 mm×7.5 mm) columns. The system was fitted with a Model 2487 differential refractometer detector and anhydrous tetrahydrofuran was used as the mobile phase (1 mL/min flow rate). Infrared (IR) spectroscopy was implemented using a NEXUS 670 FT-IR E.S.P. (Madison, Wis.). Samples were made using approximately 4 mg of polymer and five 5 mg of KBr which was then ground into a fine powder by mortar and pestle and compacted into a pellet. All proton nuclear magnetic resonance (NMR) analysis was obtained from a 400 MHz Varian Mercury spectrometer (Palo Alto, Calif.), using TMS=0.00 ppm calibration and performed at room temperature with deuterated chloroform as the solvent. Microwave irradiation reactions were carried out using a Discover CEM Microwave Reactor (Matthews, N.C.).
EXAMPLE 1
Polymerization of poly(N-acylethylenimine) (PNAI)
PNAI was polymerized with propargyl toluene-4-sulfonate as the initiator to introduce an alkyne onto the polymer endgroup. Propargyl tosylate was stirred with CaCO 3 overnight to remove any free protons, filtered, and dried on the pump. A round bottom flask with magnetic stir bar attached to a condenser was flame dried to remove any water. Varying initiator to monomer ratios were used to target molecular weights between 1500 and 12000. For example, propargyl toluene-4-sulfonate (0.6053 mmol) and acetonitrile (5 mL) was added to the round bottom flask under N 2 gas and cooled in an ice bath. 2-ethyl-2-oxazoline (30.2633 mmol) was then added via syringe to the round bottom flask. The reaction mixture was stirred under nitrogen at 65° C. for 24 hours. The reaction was cooled in an ice bath followed by the addition NaN 3 to the reaction mixture and stirred for 30 minutes. The reaction was heated to 65° C. and allowed to stir overnight. The PNAI was precipitated in diethyl ether twice and washed with NaHCO 3 . To isolate higher molecular weight polymer, further purification was performed by dissolving the polymer in 50% by volume of CHCl 2 and toluene (100 mL). Diethyl ether was added dropwise until cloudy. The solution was heated until clear and stored in a cold room overnight. The solvent was then decanted from the polymer. 1 H NMR (CDCl 3 ): δ 1-1.2(b), 2.2-2.5(b), 3.2-3.6(b); 13 C NMR (CDCl 3 ): δ 8-11(b), 25-27(b), 43-48(b); Representative Example: GPC: M n : 7000 daltons, PDI: 1.04; MALDI-TOF MS: M n : 12000 daltons, PDI; 1.01.
EXAMPLE 2
Polymerization of poly(N-acylethylenimine) (PNAI) (with Microwave Reactor)
PNAI was polymerized with propargyl toluene-4-sulfonate as the initiator to introduce an alkyne into the polymers. Propargyl tosylate was stirred with CaCO 3 overnight to remove any free protons, filtered, and dried on the pump. A microwave reaction vessel (8 mL) with magnetic stir bar was flame dried to remove any water, and filled with N 2 gas. Varying initiator to monomer ratios were used to target molecular weights between 1500 and 12000. For example, 2-ethyl-2-oxazoline (9.9062 mmol) and acetonitrile (1 mL) was added to the reaction vessel under N 2 gas and cooled in an ice bath. Propargyl toluene-4-sulfonate (0.9906 mmol) was added via syringe to the reaction vessel. The reaction mixture was reacted under microwave irradiation at 140° C. (120 watts) for 2.50 minutes. The reaction was removed from the microwave reactor and cooled in an ice bath. NaN 3 was added to the reaction mixture and stirred for 60 minutes under N 2 gas. The reaction mixture was reacted under microwave irradiation at 100° C. (120 watts) for 10 minutes and allowed to stir overnight to ensure complete termination with azide. The PNAI was then precipitated in diethyl ether and washed with NaHCO 3 . 1 H NMR (CDCl 3 ): δ 1-1.2(b), 2.2-2.5(b), 3.2-3.6(b); 13 C NMR (CDCl 3 ): δ 8-11(b), 25-27(b), 43-48(b); Representative Example: GPC: M n : 2100 daltons, PDI: 1.08; MALDI-TOF MS: M n : 20000 daltons, PDI: 1.06.
The resulting linear PNAI corresponds to the structure of Formula 7 below:
EXAMPLE 3
Cyclization of PNAI
A mass of 0.159 g of end group functionalized PNAI (0.018 mmol) was added to a 100 mL two neck round bottom flask containing a magnetic stir bar and then dissolved in 100 mL of CHCl 2 . In a separate 250 mL two neck round bottom flask equip with a stir bar N,N,N′,N′,N-Pentamethyldiethylenetriamine (PMDETA) (0.211 g, 1.21 mmol) was dissolved into 120 mL of CHCl 2 . Both reaction vessels were degassed three times via freeze pump thaw cycles during which time Cu(I)Br (0.159 g, 1.11 mmol) was added to the larger flask while frozen. Once thawed, a syringe pump with a 25 mL gas tight syringe was used to add the polymer/solvent solution to the 250 mL round bottom flask containing the Cu(I)Br/PMDETA/CHCl 2 solution at a rate of 2 mL/hr at room temperature. The syringe was filled periodically with the polymer/solvent solution until all solution was added. The reaction was then exposed to air and washed with a saturated solution of ammonium chloride (NH 4 Cl) to remove any Cu. Further removal of Cu was preformed by passing the polymer through a plug of silica with MeOH as the eluent. The polymer was then passed through a 13 mm GD/X Disposable syringe filter (PTFE filter media; polypropeylene housing; 0.2 μm pore size) with THF. NMR (CDCl 3 ): δ 1-1.2(b), 2.2-2.5(b), 3.2-3.6(b); 13 C NMR (CDCl 3 ): δ 8-11(b), 25-27(b), 43-48(b); Representative Example: GPC M n . 4600 PDI: 1.08; MALDI-TOF MS: 4900 PDI: 1.02.
The cyclized PNAI corresponds to the structure of Formula 8 below:
EXAMPLE 4
Optimized Cyclization Conditions for PNAI under 4K
A mass of 0.159 g of end group functionalized PNAI (1 mmol) was added to a 100 mL two neck round bottom flask containing a magnetic stir bar and then dissolved in 80 mL of CHCl 2 . In a separate 250 mL two neck round bottom flask equip with a stir bar N,N,N′,N′,N-Pentamethyldiethylenetriamine (PMDETA) (0.422 g, 2.42 mmol) was dissolved into 120 mL of CHCl 2 . Both reaction vessels were degassed three times via freeze pump thaw cycles during which time Cu(I)Br (0.302 g, 2.11 mmol) was added to the larger flask while frozen. Once thawed, a syringe pump with a 25 mL gas tight syringe was used to add the polymer/solvent solution to the 250 mL round bottom flask containing the Cu(I)Br/PMDETA/CHCl 2 solution at a rate of 2 mL/hr at room temperature. The syringe was filled periodically with the polymer/solvent solution until all solution was added. The reaction was then exposed to air and washed with a saturated solution of ammonium chloride (NH 4 Cl) to remove any Cu. Further removal of Cu was preformed by passing the polymer through a plug of silica with MeOH as the eluent. The polymer was then passed through a 13 mm GD/X Disposable syringe filter (PTFE filter media; polypropeylene housing; 0.2 μm pore size) with THF. NMR (CDCl 3 ): δ 1-1.2(b), 2.2-2.5(b), 3.2-3.6(b); 13 C NMR (CDCl 3 ): δ 8-11(b), 25-27(b), 43-48(b); Representative Example: GPC M n . 1500 PDI: 1.10; MALDI: M n : 1900 PDI: 1.03.
EXAMPLE 5
Acid Hydrolysis of Linear PNAI to Linear PEI
Linear PNAI (48 g/L) was dissolved in 16.8 wt % HCl (14.25 mL HCL in 83.2 mL H 2 O) reacted under reflux for 24 hours. The reaction was then cooled to room temperature and the acid solution was evaporated. Fresh deionized water was then added and the solution was neutralized with 2.5 M NaOH solution to a pH>8. The precipitated PEI was then filtered, washed with DI water, dissolved in methanol, and precipitated in diethyl ether. 1 H NMR (methanol-d): 2.6-2.8(b); Representative Example: MALDI-TOF MS: M n : 940 PDI: 1.01.
The resulting linear PEI corresponds to the structure of Formula 9 below:
EXAMPLE 6
Acid Hydrolysis of Cyclic PNAI to PEI
Cyclic PNAI (48 g/L) was dissolved in 16.8 wt % HCl (14.25 mL HCL in 83.2 mL H 2 O) reacted under reflux for 24 hours. The reaction was then cooled to room temperature and the acid solution was evaporated. Fresh deionized water was then added and the solution was neutralized with 2.5 M NaOH solution to a pH>8. The precipitated PEI was then filtered, washed with deionized water, dissolved in methanol, and precipitated in diethyl ether. 1 H NMR (methanol-d): 2.6-2.8(b). Representative Example: MALDI-TOF MS: M n : 980 PDI: 1.02.
The cyclized PEI corresponds to the structure of Formula 10 below:
All references cited in this specification are herein incorporated by reference as though each reference was specifically and individually indicated to be incorporated by reference. The citation of any reference is for its disclosure prior to the filing date and should not be construed as an admission that the present disclosure is not entitled to antedate such reference by virtue of prior invention.
It will be understood that each of the elements described above, or two or more together may also find a useful application in other types of methods differing from the type described above. Without further analysis, the foregoing will so fully reveal the gist of the present disclosure that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this disclosure set forth in the appended claims. The foregoing embodiments are presented by way of example only; the scope of the present disclosure is to be limited only by the following claims.
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Compositions comprising linear PNAI, cyclic PNAI, linear PEI, and/or cyclic PEI, useful for delivering compounds or substances into a cell, are provided, as well as methods of making linear PNAI, cyclic PNAI, linear PEI, and cyclic PEI. Also provided are methods of using compositions comprising linear PNAI, cyclic PNAI, linear PEI, and/or cyclic PEI for introducing substances into a cell.
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BACKGROUND OF THE INVENTION
1. Technical Field of the Invention
This invention relates generally to concrete support structures and in particular, to stay-in-place forms (i.e., composite shells) for forming concrete support structures.
2. Description of the Related Art
Concrete columns are commonly used as upright supports for superstructures. Bridge supports, freeway overpass supports, building structural supports and parking structure supports are just a few of the many uses for concrete columns. Other concrete support members such as beams, walls, slabs, girders, struts, braces, etc. are employed to impart strength and stability to a large variety of structures. These concrete support structures exist in a wide variety of shapes. Typically, these concrete support structures have circular, square or rectangular cross-sections. However, numerous other cross-sectional shapes have been used including regular polygonal shapes and irregular cross-sections. The size of the concrete support structures also varies greatly depending upon the intended use. Concrete columns with diameters on the order of 2 to 20 feet and lengths of well over 50 feet are commonly used as bridge or overpass supports.
Conventionally, some concrete columns have been constructed by filling a cylindrical form having a network of rebar mounted therein with a concrete composition, allowing the composition to cure, and removing the form.
Also, in the past, elongate paper fiber tubes have been used to form concrete columns. The tubes are made by spirally winding several layers of strong fiber paper. The spirally wound paper is laminated along its seams with a special adhesive. The outside of the tube can be coated with hot wax for protection against adverse weather conditions. Concrete is poured into the tube and allowed to harden so as to form a column. After hardening, the tube is stripped away from the concrete column and scrapped.
Rather than paper tubes, reusable steel or wood forms can also be used. Concrete is poured into these forms and allowed to harden. After hardening, the form is removed from the concrete structure and can be used again.
All of these conventional concrete support structures are subject to deterioration of their long-term durability and integrity. Permeability of the exposed concrete by water can cause the concrete to deteriorate over time. When moisture is trapped in the concrete and freezes, cracks typically form in the concrete structural members. In addition, some of these conventional concrete support structures are located in earthquake prone areas but do not have adequate metal reinforcement or structural design to withstand high degrees of asymmetric loading.
More recently, composites have been used to repair and retrofit columns, beams, walls, tanks, chimneys and other structural elements. However, a need exists to use composites in a prefabricated form to strengthen new constructions, protect internal reinforcing steel, provide fiber reinforcement outside of a concrete layer, to provide better appearance features, and to solve the above problems.
SUMMARY OF INVENTION
A stay-in-place composite form in accordance with the present invention provides increased strength and durability to concrete support structures. The stay-in-place form can be used in prefabricated form or can be fabricated at the construction site, to strengthen new constructions.
The stay-in-place form includes a composite shell made up of fibrous fabric layers impregnated with a resin matrix. The composite shell has an inner wall surface defining an enclosure into which concrete may be poured and allowed to harden to form a concrete core. As the concrete is poured into the enclosure, the fibers in the fabric material elongate due to the weight of the concrete. Then, as the concrete dries, the fibers partially shrink back to compensate for shrinkage of the concrete.
In one embodiment of the present invention, the percentage of elongation of the resin matrix is greater than the percentage of elongation of the fibers. Typically, the percentage of elongation of the fibers and resin matrix prevents a gap from forming between the concrete core and the composite shell when the concrete shrinks.
A liner made of a water-impermeable material is affixed to the inner wall surface of the composite shell to protect the composite shell from alkalinity or other chemical products in the concrete core. This liner is in direct contact with an outer surface of the concrete core and either completely or partially surrounds the concrete core.
In one embodiment of the present invention, the stay-in-place form is manufactured using a rigid collapsible tubular member. The exterior surface of the tubular member is wrapped with the liner and then the fabric layers impregnated with resin are applied to the liner. Once the fabric layers cure, the tube is collapsed and removed from beneath the liner. What remains is a hollow stay-in-place composite form.
In yet another embodiment of the present invention, the stay-in-place form is manufactured using a mandrel. In such embodiment, the liner is applied to an exterior surface of the mandrel and then the fabric layers impregnated with resin are applied to the liner. Once the fabric layers cure, the liner and harden fabric layers are separated from the mandrel. Again, what remains is a hollow stay-in-place composite form.
In still another embodiment of the present invention, the collapsible tube or the mandrel is rotated about an axis while the fabric layer and the resin matrix is applied to the liner. Such rotation maintains the form of the tube and composite shell, and ensures that the resin is uniformly distributed. The rotation of the tube or mandrel continues until the resin impregnated fabric layers are fully cured.
These and other features and advantages of the present invention will become apparent by reference to the following detailed description and accompanying drawings which set forth several illustrative embodiments in which the principles of the invention are utilized.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective longitudinal view illustrating the stay-in-place form in accordance with the present invention;
FIG. 2 is a perspective longitudinal view illustrating a fully reinforced support structure using the stay-in-place form of the present invention;
FIG. 3 is a detailed sectional view of an exemplary reinforced composite material in accordance with the present invention;
FIG. 4 is a detailed sectional view of an alternative exemplary reinforced composite material in accordance with the present invention;
FIG. 5 depicts a weave pattern which is the same as the weave pattern shown in FIG. 4 except that the yarns are stitch bonded together;
FIG. 6 is a detailed partial section of the face of an external surface of composite shell covered with multiple fabric layers;
FIG. 7 is a perspective view of a protective liner;
FIG. 8 is a cross-sectional inner view of an alternate embodiment of the stay-in-place-form in accordance with the present invention;
FIG. 9 is a cross-sectional inner view of a second alternate embodiment of the stay-in-place-form in accordance with the present invention;
FIG. 10 is a cross-sectional inner view of a third alternate embodiment of the stay-in-place-form place-form in accordance with the present invention;
FIGS. 11A and 11B are a perspective longitudinal view and a cross-sectional inner view, respectively, illustrating a fourth alternate embodiment of the stay-in-place form in accordance with the present invention;
FIGS. 12A-12J are perspective views illustrating the steps of manufacturing a precast stay-in-place form constructed in accordance with the present invention;
FIG. 13 is a demonstrative representation depicting the impregnation of a fabric layer prior to application to the tubular form in accordance with the present invention; and
FIG. 14 is a perspective view illustrating application of a liner to a mandrel in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Stay-In-Place Form
Referring to FIG. 1, a perspective view of a stay-in-place form 100 for use as a support structure, such as a column or beam, is shown. Although stay-in-place form 100 is illustrated as an elongate tubular structure in FIG. 1, it will be appreciated that stay-in-place form 100 may be any desired shape, such as rectangular or octagonal. Stay-in-place form 100 includes an exterior composite shell 101 and a liner 103 secured to the inner surface of composite shell 101 . In this way, stay-in-place form 100 provides a hollow closed form into which a slurry of concrete or cement material 105 is placed. Slurry 105 fills stay-in-place form 100 and hardens to form a concrete core 205 of a fully reinforced support structure 200 , illustrated in FIG. 2 .
Composite shell 101 is formed of a resin-impregnated composite reinforcement layer 107 , as illustrated in FIG. 1 . Composite reinforcement layer 107 is in direct contact with the outer surface of liner 103 and may be made of a single layer of fabric, although typically reinforcement layer 107 is made up of multiple layers of fabric. In the exemplary embodiment illustrated in FIG. 1, composite reinforcement layer 107 is made of seven fabric layers 109 - 115 . Each of fabric layers 109 - 115 has first and second parallel selvedges. For example, the first and second selvedges for fabric layer 109 are shown at 109 A and 109 B, respectively. The first and second selvedges for fabric layer 110 are shown at 110 A and 110 B, respectively. In an exemplary embodiment, the width of the fabric between the selvedges may be from twelve to one hundred inches wide. Fabric layers 109 - 115 may include a single fabric layer or they may be laminates made up of two or more layers of fabric.
An exemplary fabric is shown in FIG. 3 . The fabric is preferably a plain woven fabric having warp yarns 301 and fill yarns 303 . The warp yarns 301 and fill yarns 303 may be made from the same fibers or they may be different. The fabric may be comprised of, for example, glass, carbon, boron, graphite, polyaramid, boron, Kevlar, silica, quartz, ceramic, polyethylene, aramid, or other fibers. A wide variety of types of weaves and fiber orientations may be used in the fabric. Where a single layer of fabric is used, it will often be desirable to use weft cloth containing both horizontal and vertical fibers. For example, composite reinforcement layer 107 may include vertical, horizontal and off-axis fibers which can minimize or eliminate the need for steel reinforcement in support structure 200 . Where multiple layers of fabric are used, it will often be desirable to alternate the orientation of the fibers to provide maximum strength along multiple axes. Typically, fibers oriented along the longitudinal axis provide stiffness of composite shell 101 whereas fibers oriented along the horizontal axis provide strength in the hoop direction or along the circumference of composite shell 101 . Such strengthening in the hoop direction prevents buckling of the longitudinal fibers and restricts the movement of concrete core 205 of support structure 200 in FIG. 2 .
Referring again to FIG. 3, the warp yarns 301 are preferably made from glass. The fill yarns 303 are preferably a combination of glass fibers 305 and polyaramid fibers 307 . The diameters of the glass and polyaramid fibers preferably range from about 3 microns to about 30 microns. It is preferred that each glass yarn include between about 200 to 8,000 fibers. The fabric is preferably a plain woven fabric, but may also be a 2 to 8 harness satin weave. The number of warp yarns per inch is preferably between about 5 to 20. The preferred number of fill yarns per inch is preferably between about 0.5 and 5.0. The warp yarns extend substantially parallel to the selvedge 309 with the fill yarns extending substantially perpendicular to the selvedge 309 and substantially parallel to the axis of the stay-in-place form 100 . This particular fabric weave configuration provides reinforcement in both longitudinal and axial directions. This configuration is believed to be effective in reinforcing the stay-in-place form 100 against asymmetric loads experienced by the support structure 200 of FIG. 2, during an earthquake.
A preferred alternate fabric pattern is shown in FIG. 4 . In this fabric pattern, plus bias angle yarns 401 extend at an angle of between about 20 to 70 degrees relative to the selvedge 403 of the fabric. The preferred angle is 45 degrees relative to the selvedge 403 . The plus bias angle yams 401 are preferably made from yarn material the same as described in connection with the fabric shown in FIG. 3 . Minus bias angle yarns 405 extend at an angle of between about −20 to −70 degrees relative to the selvedge 403 . The minus bias angle yarns 405 are preferably substantially perpendicular to the plus bias angle yarns 401 . The bias yams 401 and 403 are preferably composed of the same yarn material. The number of yarns per inch for both the plus and minus bias angle is preferably between about 5 and 30 with about 10 yarns per inch being particularly preferred.
It is preferred that the fabric weave patterns be held securely in place relative to each other. This is preferably accomplished by stitch bonding the yarns together as shown in FIG. 5 . An alternate method of holding the yarns in place is by the use of adhesive or leno weaving processes, both of which are well known to those skilled in the art. In FIG. 5, exemplary yarns used to provide the stitch bonding are shown in phantom at 501 . The process by which the yarns are stitch bonded together is conventional and will not be described in detail. The smaller yarns used to provide the stitch bonding may be made from the same materials as the principal yarns or from any other suitable material commonly used to stitch bond fabric yarns together. The fabric shown in FIG. 3 may be stitch bonded. Also, if desired, unidirectional fabric which is stitch bonded may be used in accordance with the present invention.
In FIG. 6, a portion of a composite reinforcement layer surrounding a concrete column is shown generally at 601 . The composite reinforcement layer 601 includes an interior fabric layer 603 which is the same as the fabric layer shown in FIG. 5 . In addition, an exterior fabric layer 605 is provided which is the same as the fabric layer shown in FIG. 3 . This dual fabric layer composite reinforcement 601 provides added structural strength when desired.
In another embodiment, the composite reinforcement layer 107 of FIG. 1 may have an inner layer of longitudinal axial fibers and an outer layer of circumferential hoop fibers. For example, the multilayer reinforcement material 107 may include a first reinforcement layer including two fabric layers of glass or carbon fibers in a longitudinal direction and a second high strength composite reinforcement layer including three layers of glass or carbon fibers in the hoop direction. In another embodiment, the high strength composite reinforcement layers have spiral layers. These fabric layers not only provide the structural integrity of the composite shell 101 , but also provide significant reinforcement against externally applied forces.
All of the fabric layers 109 - 115 must be impregnated with a resin in order to function properly in accordance with the present invention. Suitable resins for use in accordance with the present invention include polyester, epoxy, polyamide, bismaleimide, vinylester, urethanes and polyurea. Other impregnating resins may be utilized provided that they have the same degree of strength and toughness provided by the previously listed resins. Epoxy based resin systems are preferred. It is also preferred that the fiber and resin matrix are waterproof.
Referring again to FIG. 1, when slurry 105 is poured into stay-in-place form, the weight of slurry 105 elongates or stretches the fibers in reinforcement layer 107 causing these fibers to be stressed. Thus, liner 103 , reinforcement layer 107 , and the resin impregnated into reinforcement layer 107 are selected to permit elongation of the fibers when slurry 105 is poured into stay-in-place form 100 . In particular, the resin must be flexible enough to allow for such post-tensioning of the fibers. Having been elongated during the pouring of concrete 105 , the fibers are stressed, which strengthens the fibers and allows for reduced thickness of stay-in-place form 100 . These fibers will then partially shrink back or relax to compensate for concrete shrinkage as concrete slurry 105 dries. As a result, the final percent of elongation of the resin should be greater than percent of elongation of the fibers so that the reinforcement layer 107 does not crack from stress caused by the weight of the concrete. For example, in one embodiment the glass fibers have 2% elongation and the epoxy has 3-4% elongation. The percent of elongation of the resin should be balanced with the percent of elongation of the fibers so that there is some stress on the fibers from the weight of the concrete, but not so much so that there is cracking. With such a balance, the fibers are able to shrink back to compensate for concrete shrinkage once slurry 105 hardens without leaving any gaps between concrete core 205 and liner 103 of support structure 200 , illustrated in FIG. 2 .
Liner 103 is received to the inner wall surface of hollow composite shell 101 . A perspective view of liner 103 is illustrated in FIG. 7 . As shown, liner 103 is flexible so that it will conform to the inner wall surface of composite shell 101 regardless of the shape of the shell 101 . Referring again to FIG. 2, liner 103 is formed of a water-resistant and impermeable material to protect concrete core 205 from moisture and corrosive materials, as well as to protect the composite shell 101 from the alkalinity in concrete core 205 . Liner 103 can be fabricated from plastic or rubber materials such as polystyrene, vinyl, polyethylene, chlorosulfonated polyethylene, such as HYPALON, synthetic rubber, such as NEOPRENE, EPDM (ethylene-propylene-diene terpolymer), rubber, or other resistive materials.
The thickness of liner 103 should be sufficient to prevent damage when slurry 105 is poured into stay-in-place form 100 . For example, if liner 103 is too thin, the weight of the slurry 105 may tear liner 103 as it is poured into stay-in-place form 100 . In an exemplary embodiment, the thickness of liner 103 is between {fraction (1/64)} and ¼ of an inch.
Stay-in-place form 100 is filled with slurry 105 which hardens within stay-in-place form 100 to form a concrete core 205 of structural member 200 shown in FIG. 2, such as a column or beam. Stay-in-place form 100 is not removed from concrete core 205 , but rather remains in place to increase the shear strength and longevity of support structure 200 over that of conventional support structures.
One way to increase the structural integrity of concrete structural member 200 , illustrated in FIG. 2, is to attach reinforcing bars to the inner surface of stay-in-place form 100 . FIG. 8 illustrates an alternate embodiment of the present invention, in which a cross-section of stay-in-place form 800 is shown with reinforcing bars 801 , 809 . Stay-in-place form 800 has the same outer composite shell 101 and liner 103 , but also has reinforcing bars 801 , 809 such as steel or composite reinforcing bars, secured to the inner surface of stay-in-place form 800 to provide further reinforcement.
As shown in FIG. 8, anchors or stiffener tabs 803 are received by grooves 805 and are distributed about the inner wall surface of stay-in-place form 800 . These anchors 803 extend horizontally from the inner wall surface of composite shell 101 , through liner 103 , and terminate within the enclosure of stay-in-place form 800 . In one embodiment, anchors 803 terminate in clamps 807 that are used to hold vertically extending reinforcing bars 801 . With such configuration, reinforcing bars 801 can be pre-installed at the factory or snapped into clamps 807 at the construction site. In an alternate embodiment, vertically extending reinforcement bars 809 are integrally formed with anchor 805 .
As shown in FIG. 8, vertically extending reinforcing bars 801 , 809 may extend a partial length of composite shell 101 . Alternatively, referring to the cross-section view of stay-in-place form 900 illustrated in FIG. 9, vertically extending bars 901 , 903 may extend along a substantial length of composite shell 101 . Also, referring to the cross-section view of stay-in-place form 10 illustrated in FIG. 10, reinforcing bars 1001 may extend across the enclosure within stay-in-place form. It also will be appreciated that although reinforcing bars are illustrated as vertically and horizontally reinforcement bars in FIGS. 8-10, reinforcement bars can be situated in other positions, such as diagonally or circumferentially.
Stay-in-place forms 100 and 800 , illustrated in FIGS. 1 and 8 respectively, have been disclosed as complete tubular or columnar enclosures. However, stay-in-place forms may also be partial enclosures. FIG. 11A illustrates a perspective view of a stay-in-place form 1100 that has a horizontally extending hollow rectangular channel shape. Stay-in-place form 800 includes a horizontally extending hollow channel composite shell 1101 and a liner 1103 secured to the inner surface of composite shell 1101 . In this way, stay-in-place form 1100 provides a channel form into which a slurry of concrete or cement material 105 is placed, which upon hardening, creates a fully reinforced support structure. With this configuration, stay-in-place form 1100 only partially surrounds a concrete core and may be used, for example, to construct beams. Since the upper portion of the channel shaped stay-in-place form 1100 is open, the beam can easily connect to another support structure (not shown).
Referring now to FIG. 11B, a cross-sectional view of stay-in-place form 1100 along line A—A is illustrated. As shown in FIG. 11B, stay-in-place form 1100 includes reinforcement bars 1105 that extend across the width of the channel-shaped composite shell 1101 , to provide additional reinforcement. In addition, stay-in-place form 1100 also includes built-in connectors 1107 , which may be made of various materials such as fiber composite, steel, etc., formed into composite shell 1101 to connect the completed beam with another support structure, such as a column, foundation or other beam. Stay-in-place form 1100 may also include anchors at the edges or other areas of composite shell 1101 to further reinforce the completed support structure. In all of these embodiments, reinforcement bars 1105 and anchors 1107 are designed to withstand the stresses of concrete slurry 105 that is to be poured into the enclosure.
Stay-in-place forms 100 , 800 , 900 , 1000 , 1100 can be used as a cast-in-place structural member where the construction of the stay-in-place form is done at or near a construction site. Alternatively, stay-in-place forms 100 , 800 , 900 , 1000 , 1100 can be used as precast members, where construction of the stay-in-place form is done in a factory and is then shipped to the construction site.
Method of Manufacturing Stay-In-Place Form
FIGS. 12A-12J illustrate the sequence of steps employed to fabricate stay-in-place form 100 using a reusable form 1201 such as that illustrated in FIG. 12 A. Care should be taken in selecting the shape of reusable form 1201 , as the shape of reusable form 1201 will determine the shape of resulting stay-in-place form 100 . In the embodiment illustrated in FIG. 12A, reusable form 1201 is a tubular form. In this FIG. 12A a perspective view of tubular form 1201 is shown. In an exemplary embodiment, tubular form 1201 is fabricated from a fiber paper which is formed by spirally winding and laminating the fiber paper together with a special adhesive along seams 1203 . Although, tubular form 1201 is fabricated from fiber paper, it will be appreciated that tubular form 1201 can be fabricated from other types of material so long as tubular form 1201 is rigid and collapsible.
A small slit or groove 1205 is cut into the inner surface of tubular form 1201 , as illustrated in FIG. 12 B. Referring now to FIGS. 12C and 12D, a cross-sectional view of tubular form 1201 is shown along line B—B. As shown in FIG. 12C, a tool 1207 such as a steel blade, is able to grasp the small slit 1205 . This enables a portion of tubular form 1201 to be pulled inward as illustrated in FIG. 12D, thereby reducing the diameter of tubular form 1201 . The importance of this collapsing of tubular form 1201 will be explained later in the specification.
FIG. 12E illustrates a perspective view of tubular form 1201 lying on its side. Water bags 1208 , illustrated with phantom lines, may be placed inside tubular form 1201 to maintain the shape of tubular form 1201 during the fabrication process of stay-in-place form 100 . It will be appreciated that although water bags 1208 are illustrated to maintain the shape of tubular form 1201 , it will be appreciated that other devices, such as mechanically expandable wood or steel, placed at the ends of tubular form 1201 , can be used for the same purpose.
Once water bags 1208 have been inserted into tubular form 1201 , liner 103 is applied to tubular form 1201 . FIG. 12F, illustrates a top plan view of liner 103 being applied to the outer surface of tubular form 1201 . Liner 103 is wrapped tightly around tubular form 1201 such that the lateral edges of liner 103 overlap and are held together with an adhesive material such as tape or glue. In some instances it is desirable to prevent at least one end of liner 103 from slipping relative to tubular form 1201 . In such instances, liner 103 may be adhered to tubular form 1201 , such as by applying tape, glue or some other adhesive material to liner 103 , tubular form 1201 or both.
Once liner 103 has been wrapped around tubular form 1201 , a composite reinforcement layer 107 , as illustrated in FIG. 1, is applied to the exposed outer surface of liner 103 , as illustrated in FIG. 12 G. As explained above in reference to reinforcement layer 107 , such reinforcement layer may be applied in a variety of different patterns and may be made up of multiple layers of fabric. In the exemplary embodiment illustrated in FIG. 1, composite reinforcement layer 107 is made up of fabric layers 109 - 115 . All of the fabric layers 109 - 115 must be impregnated with a resin in order to function properly in accordance with the present invention. Preferably, the resin is impregnated into the fabric prior to application to the exterior surface of liner 103 . However, if desired, the resin may be impregnated into the fabric after the fabric is wrapped around the liner.
As illustrated in FIGS. 12G-12H, fabric layers 109 - 115 are resin impregnated prior to application to liner 103 so that the final fabric layers 109 - 115 are provided within a resin matrix. For example, referring to FIG. 13, a fabric 1301 is shown being unwound from roll 1303 and dipped in resin 1305 for impregnation prior to application to liner 103 . Once a sufficient length of fabric 1301 has been impregnated with resin 1305 , the impregnated fabric layer is cut from roll 1303 and is applied to the exterior surface of liner 103 , as shown in FIGS. 12G-12H. The length of impregnated fabric is chosen to provide either one wrapping or multiple wrappings of liner 103 . Once in place, the resin impregnated fabric layer is allowed to cure to form the composite reinforcement layer 107 .
In an alternate embodiment, fabric layers 109 - 115 are impregnated with resin after being wrapped around liner 103 . In either embodiment, it is preferable that tubular form 1201 be rotated around an axis B in a direction indicated by arrow A, as shown in FIG. 12G, while the fabric layers are wrapped around liner 103 . Such rotation maintains the form of tubular form 1201 and ensures that the resin is uniformly distributed. Tubular form 1201 may be suspended or rotated on a platform while this rotation takes place. The rotation of tubular form 1201 continues until the resin impregnated fabric layers are fully cured.
Curing of the resins is carried out in accordance with well known procedures which will vary depending upon the particular resin matrix used. The various catalysts, curing agents and additives which are typically employed with such resin systems may be used. The amount of resin which is impregnated into the fabric is preferably sufficient to saturate the fabric.
Once the fabric layers are fully cured, tubular form 1201 is pulled out from liner 103 . One technique for removing tubular form 1201 is to use a release tool 1207 , such as a steel blade, as illustrated in FIGS. 12C-12D. Release tool 1207 is inserted into slit 1205 as illustrated in FIG. 12 C. Pulling on release tool 1207 , causes a portion of tubular form 1201 to be pulled inward and away from liner 103 , thereby reducing the diameter of the form 1201 , as shown in FIGS. 12 D. FIGS. 12I-12J further illustrate the collapsing of tubular form 1201 . FIG. 12I illustrates a cross-sectional view along line B of liner 103 and composite reinforcement layer 107 wrapped around tubular form 1201 as shown in FIG. 12 G. FIG.12J illustrates a top plan view of tubular form 1201 being collapsed inward and away from liner 103 . Using this technique, tubular form 1201 can be collapsed and pulled out from beneath liner 103 . Once tubular form 1201 is pulled out, the resulting structure is stay-in-place form 100 , illustrated in FIG. 1 .
In an alternate embodiment, stay-in-place form 100 is formed using a mandrel, as illustrated in FIG. 14 . In such an embodiment, mandrel 1401 serves as a core around which liner 103 is wrapped, as illustrated in FIG. 14 . Composite reinforcement layer 107 impregnated with the resin is then continuously wrapped around liner 103 until a desired thickness is obtained, as illustrated in FIGS. 12G and 12H. Once the fibers are cured, liner 103 and the hardened shell formed from composite reinforcement layer 107 are slipped off mandrel 1401 . In either embodiment, the resulting structure is stay-in-place form 100 .
Various other modifications and alterations in the structure and method of operation of this invention will be apparent to those skilled in the art without departing from the scope and spirit of this invention. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments.
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A stay-in-place composite form provides a strong and durable concrete structure. The form includes a composite shell having an inner wall surface defining an enclosure into which concrete may be poured and allowed to harden. The composite shell may be made of one or several layers of fabric having a resin matrix impregnated therein. The concrete hardens to form a concrete core within the enclosure and a liner is affixed to the inner wall surface of the composite shell to protect the composite shell from alkalinity in the concrete core. The liner includes at least one sheet of a water-impermeable material to protect the concrete core from water and other corrosive elements. The fabric layers are selected such that the fibers elongate as the concrete is poured into the enclosure due to a weight of the concrete and partially shrink back to compensate for shrinkage of the concrete as the concrete dries to form the concrete core. Such stay-in-place composite form can be used in prefabricated form to strengthen new constructions.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a national stage application pursuant to 35 U.S.C. §371 of International Application No. PCT/AU2013/000570, filed May 30, 2013, which claims priority to Australian Patent Application No. 2012902251, filed May 30, 2012, the disclosures of which are hereby incorporated by reference herein.
FIELD OF THE INVENTION
The present invention relates to the detection and measurement of silt depth in a fluid flow network.
BACKGROUND OF THE INVENTION
In our International Patent Application No. PCT/AU2010/001052 (published as WO 2011/020143), the entirety of which is herein incorporated, there are disclosed flow meter assemblies and methods of flow measurements.
In traditional flow measurement technologies (such as electromagnetic flow meters) flow is determined by multiplying the known cross-sectional area of a pipe or channel by the average velocity passing through this known cross section. Typically, there is one flow velocity sensor, and the average velocity is determined using this sensor. Flow is derived by multiplying the total cross sectional area of the said pipe or channel by this average velocity. The problem with this measurement technology is that the use of the average velocity multiplied by the total cross sectional area allows significant errors to occur. Unfortunately, silt may build up in the pipe or channel, reducing the cross-sectional area of the pipe or channel. Because the area through which fluid flows in a silted pipe or channel is reduced relative to a clean pipe or channel, the area assumed in the flow measurement calculation is greater than the true cross-sectional area through which the fluid flows. The flow continues to be calculated by multiplying the average velocity by the assumed cross-sectional area of the conduit. This will result in significant errors in determining the flow rate.
The above problems were lessened using the systems disclosed in our International Patent Application No. PCT/AU2010/001052. This system provided a flow meter that uses the ‘time of flight’ acoustic or ‘transit time’ method to measure multiple velocities at multiple slices through the cross-sectional area of the flow meter. The system provided a multi-path analysis of velocity across a pipe or channel at a number of horizontally disposed layers. The method of computing flow is to first compute the velocity within each discrete horizontal layer. The velocity within each layer is then multiplied by the width and the height of that layer to determine the flow passing through that layer. The flows passing through each layer are then summed to determine the total flow passing through the cross-section of the meter. The flow through the conduit is therefore the sum of each discrete flow layer. Such a calculation, using multiple sensors, provided an accurate determination of flow.
When silt accumulates, the cross sectional area of the conduit changes. At the same time, the actual velocity profile within this cross-section changes. Because the flow velocity at the silt-water interface is zero, the bottom path velocity decreases. To maintain the same flow rate through the pipe or channel, the remaining path velocities must increase slightly. Because multiple velocity measurements are made at known elevations within the meter cross section, the actual velocity profile is used to calculate the flow rate. The error in the calculated flow will be reduced compared with the traditional flow measurement technology previously described which uses a single velocity measurement to compute flow.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide a method of detecting silt in a fluid flow network.
A further object of the present invention is to enhance the accuracy of measurement of fluid flow in a fluid flow network under arduous conditions.
SUMMARY OF THE INVENTION
The present invention in one embodiment provides a method of detecting a buildup of silt in a pipe or open channel of a fluid flow network, said pipe or open channel having at least one set of vertically spaced velocity sensors to measure flow velocities at predetermined horizontal levels, said method including the steps of computing the flow using the measured flow velocities and cross-sectional areas for each flow layer, and summing said flows to provide a total flow at said at least one set of vertically spaced velocity sensors, monitoring said measured flow velocities and storing said flow velocities to detect any ongoing reduction in the flow velocity of at least the lowermost velocity sensor at a selected total flow whereby said ongoing reduction provides an indication of a buildup of silt in said pipe or open channel.
The invention may also provide a method of measuring a build up of silt in a pipe or open channel of a fluid flow network, said pipe or open channel having a system having at least one set of vertically spaced velocity sensors to measure flow velocities at predetermined horizontal levels, said method including the steps of monitoring said measured flow velocities and storing said flow velocities, calibrating said system to provide a silt-free velocity profile of said at least one set of vertically spaced velocity sensors and a plurality of velocity profiles at predetermined silt depths to allow a relationship to be calculated between silt depth and the flow velocity of at least the lowermost velocity sensor at a selected total flow as the reduction in the flow velocity of said at least the lowermost velocity sensor is proportional to the depth of silt, and calculating the depth of silt based on the flow velocity of said at least the lowermost velocity sensor at a selected total flow and said relationship.
In yet a further embodiment there is provided a method of measuring the flow rate of fluid in a pipe or open channel of a fluid flow network, said pipe or open channel having a system having at least one set of vertically spaced velocity sensors to measure flow velocities at predetermined horizontal levels, said method including the steps of the previous paragraph, reducing the calculated cross-sectional area of lowermost flow layers by using the calculated depth of silt, computing the flow using the measured flow velocities and cross-sectional areas for each flow layer, and summing said flows to provide a total flow at said at least one set of vertically spaced velocity sensors.
BRIEF DESCRIPTION OF THE DRAWINGS
The structure and functional features of a preferred embodiment of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a graphical representation of the depth of the pipe or channel against the velocity detected by respective velocity sensors at differing heights in the pipe or channel with no silt present in the pipe or channel;
FIG. 2 is a similar graphical representation to that shown in FIG. 1 but includes the additional graph showing the effects of a layer of silt in the pipe or channel;
FIG. 3 is a similar graphical representation to that shown in FIG. 1 showing the correction made by an aspect of the invention where the graph has been corrected for the presence of the silt layer;
FIG. 4 is a combination of the graphs shown in FIGS. 1 and 3 ;
FIG. 5 is a similar graphical representation to that shown in FIG. 2 but showing the effects of the silt at differing silt depths;
FIG. 6 is a graphical representation of the silt depth calculation curve of the computed silt depth against the division of the velocity of the lowermost sensor by the velocity of the higher adjacent sensor to the lowermost sensor to allow determination of the silt depth according to another aspect of the invention;
FIG. 7 is an isometric view of a preferred embodiment of the flow measurement system detailed in our International Patent Application No. PCT/AU2010/001052. This preferred embodiment is a square-section meter assembly featuring eight horizontal planes of velocity measurement;
FIG. 8 is a side section view of the meter assembly referred to in FIG. 7 showing eight horizontal planes of velocity measurement; and
FIG. 9 is a plan section view of the meter assembly referred to in FIG. 7 , showing the cross-path acoustic transit measurement technique used to determine the average velocity within each horizontal velocity measurement plane of the flow meter.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment is an enhancement of the invention disclosed in International Patent Application No. PCT/AU2010/001052. In order to reduce repetition of description, the whole contents of International Patent Application No. PCT/AU2010/001052 (published as WO 2011/020143) are herein incorporated into this specification. The present invention can be used with any one of the embodiments shown in FIGS. 1 to 25 and 28 to 47 of International Patent Application No. PCT/AU2010/001052. The velocity sensors used are preferably pairs of acoustic sensors as disclosed in the PCT specification. Other sensors may be used, for example, electromagnetic sensors with electrodes set at various heights in the pipe or channel. The type of sensor is not critical but it must measure the fluid velocity accurately.
FIG. 7 is a perspective view of a preferred embodiment of the flow measurement system 100 . This preferred embodiment is a square-section meter assembly, featuring eight horizontal planes of velocity measurement, numbered 101 through 108 . Any number of horizontal measurement planes may be used in this invention, from a minimum of two measurement planes to as many measurement planes as may be practicably incorporated into the meter assembly. FIG. 7 shows eight (8) velocity sensors V1 to V8 ( FIG. 8 ) but the invention is not limited to that number. The number of velocity sensors can be increased or decreased depending on the environment where flow measurement is required.
FIG. 8 is a side section view of the meter assembly of FIG. 7 showing eight horizontal planes of velocity measurement, 101 - 108 . Within each measurement plane 101 - 108 there is a velocity measurement sensor, comprising four acoustic transducers within each plane. These transducers cooperate to provide a cross-path acoustic transit time velocity measurement within their horizontal plane, as detailed in International Patent Application No. PCT/AU2010/001052. In the preferred embodiment, each plane contains four acoustic transducers, however any number of transducers could be used as is practicable.
FIG. 9 is a plan section view of the meter assembly referred to in FIG. 7 , showing the cross-path acoustic transit measurement plane 101 . It can be seen that there are four transducers in this plane, labeled 101 a , 101 b , 101 c , 101 d . These transducers are used to measure the average flow velocity within the measurement plane as detailed in the PCT Application No. PCT/AU2010/001052.
FIG. 1 is a graphical representation of the velocities measured within each of the velocity measurement planes 101 - 108 . Note that this view only shows the bottom five measurement planes 101 - 105 . The elevation of each velocity measurement plane is plotted on the y axis 10 , and the velocity measured within each respective plane is plotted on the x-axis 12 . FIG. 1 shows a typical velocity profile within the flow meter when there is no silt present on the bottom or base 14 of the meter (or the pipe or channel into which it is installed). It is a known scientific fact that the velocity at boundary layers is zero i.e. at the bottom or base 14 and the top (not shown) for a pipe. This is readily seen at point 16 . The velocity will increase at distances offset from the boundary.
The graph shows the velocities 18 to 26 sensed within respective measurement planes V1 to V5 and the resulting plot or curve 28 is shown. The system provides a multi-path analysis of velocity across the pipe or channel at a number of horizontal layers 50 to 58 . The method of computing flow is to first compute the flow (velocity multiplied by cross sectional area) for each discrete layer. The flow through the pipe or channel is therefore the sum of each discrete flow layer. The area resulting from the integration of these velocity samples (the shaded region 48 ) is equal to the flow passing through the system per unit width of the meter. Such a calculation, using multiple sensors V1 to V8 provides an accurate determination of flow.
FIG. 2 is a similar graph to that of FIG. 1 but has an overlay plot or curve 30 resulting from a layer of silt at a depth 34 . The velocities are measured by the sensors V1 to V4 and the velocities are shown as points 36 to 42 . The graph illustrates the effect on the velocities at the same flow rate in the presence of silt 32 . The velocity at point 36 for sensor V1 has been reduced whereas the velocities at points 38 to 42 have increased to compensate. The system extrapolates the velocity measured in the plane of sensor V1 down to the known zero velocity 16 on the floor 14 of the flow meter or channel or pipe. This extrapolation in the absence of silt is shown by the line connecting the points 18 and 16 . The extrapolation in the presence of silt is shown by the line connecting the points 36 and 16 . Because the flow velocity at and below the silt depth 34 is zero, the extrapolation will over-estimate the mean velocity below the bottom measurement plane. It is not known that the silt 32 is present and so it is not known that the velocity at and below elevation 34 is equal to zero. The error in velocity extrapolation and flow measurement is indicated by the shaded area 46 encompassed by lines joining point 16 to 44 (depth of silt), joining point 44 to 36 , and joining point 36 to 16 . The error is bounded in that the deeper the silt the smaller the velocity measured on plane V1 and hence the smaller the area of error; and conversely the shallower the silt the smaller the area of error. Accordingly, the detection of any ongoing reduction in the flow velocity of sensor V1 at a selected total flow will provide an indication of a buildup of silt in said pipe or open channel. The flow measurement accuracy is still maintained as the silt builds up. The device naturally compensates for this because of the method of measuring flow i.e. computing the flow for each individual layer, rather than traditional techniques of obtaining the average velocity for the whole cross section and then multiplying by the total area. As the silt builds up the flow through the bottom layer reduces and therefore any error associated with that measurement is also reduced. If the silt covers sensor V1 the system will still provide an accurate measurement of flow.
Flow disturbance tests have confirmed that the system maintains accuracy for this type of disturbance resulting from silt. The installation of a 25% by meter depth silt layer at the floor of the system allowed accuracy to be maintained under these conditions. Importantly, this same principle holds regardless of how many measurement planes are covered by silt or other obstructions. This method of flow measurement can be in combination with or without a gate.
The above embodiment shown in FIGS. 1 and 2 allows the detection of silt and provides a system that maintains a fair degree of accuracy under varying silt depths. In order to further increase the accuracy of the system the depth of silt must be calculated. In order to reduce repetition of description the same reference numerals have been used in FIGS. 3 to 5 for similar integers in FIGS. 1 and 2 . The system uses the bottom path velocity 36 measured by sensor V1 to determine the depth of silt 34 which has accumulated on the floor 14 of the system. We are assuming that sensor V1 is not covered by silt. If sensor V1 is covered by silt then sensor V2 would be used to calculate the depth of silt. The system velocity profile under silt-free conditions is known as a result of a master calibration and is shown in FIG. 4 as curve 28 . The effect of silt is to reduce the bottom path velocity below its value observed under silt-free conditions 18 to a reduced value 36 as shown in FIG. 2 . The reduction in bottom path velocity at sensor V1 is proportional to the depth of silt on the floor 14 of the system. By comparing the velocity measured on the bottom path 50 to the velocities measured on paths 52 to 58 of the system, the deviation of bottom velocity 36 resulting from silt build up is determined. FIG. 5 shows the calibration required by showing the velocities measured at zero depth of silt by curve 28 , curve 30 at depth 34 and curve 60 at depth 62 . From these calibrations it has been determined that the silt depth can be plotted against the sensor velocities of the ratio V1/V2 of the lowermost sensor V1 to the adjacent sensor V2 to provide the curve 64 shown in FIG. 6 . From the graph shown in FIG. 6 the curve 64 allows the calculation of any depth of silt using the measurements of the sensor velocities V1 and V2. A relationship has thus been determined between the reduction in bottom path velocity and depth of silt. This relationship is known to hold approximately constant across the full range of flow rates that the system operates under.
If silt has covered the bottom velocity sensor V1, then the silt detection algorithm operates by comparing the velocity measured by sensor V2 to that measured by V3. Likewise, if the velocity sensor V2 is covered by silt then the silt detection algorithm operates by comparing the velocity measured by sensor V3 to that measured by sensor V4. Silt causes a null-read or a zero velocity measurement to be recorded by velocity sensors which are buried below silt, and this fact is used to identify which velocity sensors are buried below silt. The silt detection algorithm measures the depth of silt above the highest buried velocity sensor by comparing the ratio of the velocity measurements of the two velocity sensors located above the highest buried velocity sensor.
Given measurement of the reduction in the bottom path velocity, the depth of silt is calculated. The floor 14 of the system is then set equal to this silt depth, and the velocity integration is only performed down to this silt depth floor. This means that only the area of flow is integrated, and the zero flow silt region is excluded from the velocity integral. Hence the system detects the depth of silt and integrates the velocity profile from the internal ceiling of the system down to the silt floor 32 . This integration provides a highly accurate measurement of fluid flow passing through the system. The system accordingly has a flow measurement accuracy unaffected by silt. FIG. 3 graphically shows the integrated curve 66 based on point 44 being shifted to the depth 34 of silt at the level of the silt.
FIG. 4 graphically illustrates the curve 66 of FIG. 3 compared with the silt-free curve 28 of FIG. 1 . The detection of silt in the embodiments of FIGS. 1 to 6 can also allow a silt alarm to be incorporated into the system. An alarm can be activated by a predetermined level of silt to warn operators of the buildup of silt. Operators could then take action to remove the silt under a maintenance regime.
The invention will be understood to embrace many further modifications as will be readily apparent to persons skilled in the art and which will be deemed to reside within the broad scope and ambit of the invention, there having been set forth herein only the broad nature of the invention and certain specific embodiments by way of example.
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The invention relates to a method of detecting a buildup of silt in a pipe or open channel of a fluid flow network. The pipe or open channel has a system with at least one set of velocity sensors to measure flow velocities at predetermined horizontal levels. The method includes the steps of computing flow using measured flow velocities and cross-sectional areas for each flow layer, summing the flows to provide a total flow, monitoring the measured flow velocities and storing the measured flow velocities to detect any ongoing reduction in flow velocity of at least a lowermost velocity sensor to provide an indication of a buildup of silt in the pipe or open channel.
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RELATED APPLICATION
This application claims the benefit of EP 04 008 051.7, filed on Apr. 2, 2004, the contents of which are incorporated herein.
FIELD OF THE INVENTION
This invention is related to the field of producing non-woven fabric or fleece made from fiber material. More particularly, the invention relates to machinery known as a cross lapper.
BACKGROUND OF THE INVENTION
When laying a fiber web (hereinafter referred to as web) onto an output conveyor, the laying arm of the cross lapper performs a pivoting movement, wherein its lower, free end moves in close distance over the output conveyor transversely to the transport direction of the latter. If the upper end of the laying arm is pivotally attached on a pivotally mounted supply arm, the supply arm also performs a pivoting movement. A cross lapper of this type, also referred to as a camel back cross lapper, is generally known and, for instance, is described in the book “Vliesstoffe”, Verlag Wiley-VCH, Weinheim, 2000 (page 160).
In known camel back cross lappers, the lower end of the laying arm is coupled to a carriage which is movably guided on rails transversely to the transport direction of the output conveyor. The carriage is connected to a drive means so that by the aid of this drive means, the pivoting movement of the laying arm, and possibly of the supply arm, is carried out.
The speed at which the web is discharged by the laying arm of the cross lapper may be more than 200 m/mm, but speeds in the range of 300 m/mm are desirable. The free end of the laying arm must therefore move correspondingly fast over the output conveyor to prevent disturbing the material and the creation of folds in the layered web. These high speeds lead to problems caused by aerodynamic effects. A web section layered by the laying arm may lift off its base and start fluttering under the influence of aerodynamic pull. One approach to alleviate this effect has been to provide a garnished pressure roller which felts the fibers of the freshly layered fiber web with the fibers of the web layers already layered arranged underneath. Since a laying arm usually discharges fiber web in both of its movement directions, two such pressure rollers may be mounted at the laying arm, increasing the weight of the laying arm accordingly. Further, the effect caused by such pressure rollers is relatively moderate.
OBJECTS OF THE INVENTION
It is an object of the invention to provide improved fleece laying apparatus which overcomes some of the problems and shortcomings of the prior art, including those referred to above.
Another object of the invention to provide a cross lapper capable of working at a relatively high laying speed.
Another object of the invention is to provide a cross lapper which holds the fiber web along all essentially all of its path through the cross lapper.
Another object of the invention is to provide a cross lapper which improves the quality of the fleece material produced therein.
Still another object of the invention is to provide a cross lapper which eliminates aerodynamic effects on the product manufactured.
How these and other objects are accomplished will become apparent from the following descriptions and the drawings.
SUMMARY OF THE INVENTION
The apparatus of this invention is a cross lapper for manufacturing a fiber fleece from a fiber web. The apparatus comprises: (1) a supply arm having lower and upper ends and pivotably mounted at its lower end around a stationary lower pivot axis; (2) a downwardly extending laying arm having upper and lower ends and pivotably supported at its upper end on the supply-arm upper end around an upper pivot axis parallel to the lower pivot axis, the laying-arm lower end being movable in a substantially straight path; (3) an endless output conveyor extending substantially parallel to the pivot axes and having a laying zone below the path of the laying-arm lower end; (4) two reversing rollers supported on a common carriage that is disposed below the output conveyor and is movable transversely thereto; (5) two endless transport belts juxtaposed for clamping and transporting the fiber to be layered and guided along the supply and arms for receiving a fiber web at an infeed zone and for laying the fiber web in the laying zone on the output conveyor under pivoting movement of the supply and laying arms, the juxtaposed belts forming a discharge nip at the laying-arm lower end, the belts extending beyond the nip in opposite directions transversely across the laying zone in proximity to the output conveyor, the belts being separately guided to the reversing rollers, back to the laying-arm lower end, and from there along the laying and supply arms to the infeed zone; and (6) drive apparatus for moving the belts, pivoting the supply and laying arms, and moving the output conveyor.
Preferred embodiments of the inventive cross lapper further include a pair of discharge nip rollers supported on the laying-arm lower end, and the transport belts each pass over one of the nip rollers.
In another embodiment of the inventive cross lapper, the laying-arm lower end and the carriage are connected to one another and to the drive apparatus by one of a traction rope, a toothed belt or a chain for pivoting movement of the laying and supply arms.
In a preferred embodiment, the inventive cross lapper also includes a pair of discharge nip rollers supported on the laying-arm lower end, and the transport belts each pass over one of the nip rollers.
In another preferred embodiment, the cross lapper further includes a pivot frame pivotably coupled to the laying lower end around an axis between and parallel to the nip rollers. The pivot frame is adapted to pivot such that the nip roller which is forward in the movement direction of the laying arm lower end is lifted and the other nip roller is lowered.
In a highly-preferred embodiment, the inventive cross lapper also includes web buffering apparatus disposed upstream of the supply-arm lower end, and the buffering apparatus guides the transport belts. In this embodiment, the transport belts each include feed sections and return sections. Along the feed sections, the belts, in juxtaposed fashion, transport the fiber web from a take-up site to the discharge nip, the juxtaposed belts running through a substantially U-shaped feed path portion substantially half-wrapped over a first deflecting roller. Along the return sections, the belts move from the supply arm to the take-up site guided through U-shaped return path portions oriented in directions opposite to the orientation of the U-shaped feed path portion, each belt half-wrapping one of second and third deflecting rollers, respectively. The web buffering apparatus includes a common mounting frame rotatably supporting the three deflecting rollers, thereby providing compensated length variation of the transport belts extending to and returning from the discharge nip as the laying lower end traverses the laying zone on the output conveyor.
In another preferred embodiment of the inventive cross lapper, the laying lower end and the carriage are connected to one another and to the drive apparatus by one of a traction rope, a toothed belt or a chain for pivoting movement of the laying and supply arms.
In other embodiments, the common mounting frame is movably held in a machine stand, and in some embodiments, the common mounting frame is movably held by a pendulum.
In some preferred embodiments of the inventive cross lapper, the common mounting frame is pivotably supported around the axis of the first deflecting roller.
In another preferred embodiment, the cross lapper also includes a tensioning roller about which the belt from one of the U-shaped return path portions is substantially half-wrapped, and the tensioning roller is biased away from the U-shape of such return path portion.
In other embodiments, the cross lapper of this invention further includes first and second independent drive rollers and a common drive roller, and the transport belts are each guided over one of the independent drive rollers and their feed sections are commonly guided over the common drive roller. In these embodiments, the common drive roller is driven at a circumferential speed that is variable with respect to the circumferential speeds of the first and second independent drive rollers, thus varying the discharge speed of the cross lapper with respect to its take-up speed.
In another embodiments, the cross lapper further includes first and second independent drive rollers, the transport belts each being guided over one of the independent drive rollers, and the first deflecting roller is also a driven roller driven at a circumferential speed that is variable with respect to the circumferential speeds of the first and second independent drive rollers; thus the discharge speed of the cross lapper is varied with respect to its take-up speed.
In another preferred embodiment, the inventive cross lapper further includes two return drive rollers, and each of the return sections between the supply arm and the U-shaped return path portions wrap at least 90° around a respective one of the return drive rollers.
In highly preferred embodiments, the supply and laying arms each have guide rollers alternatingly contacting opposite sides of the juxtaposed feed sections of the transport belts.
In other highly preferred embodiments, the inventive cross lapper further includes two return drive rollers, each of the return sections between the supply arm and the U-shaped return path portions wrap at least 90° around a respective one of the return drive rollers.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically shows a side view of a camel back cross lapper according to the invention with a web buffering apparatus in retracted condition of the feeding and laying arms. The figure also shows web buffering apparatus.
FIG. 2 shows the camel back cross lapper of FIG. 1 with the feeding and laying arms in an extended position.
The drawings show the essential features only of the invention, and this in schematic view only, since a schematic view is sufficient for understanding the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a cross lapper 1 with a supply arm 2 and a laying arm 3 . The supply arm 2 is pivotally supported on its lower end in a lower, stationary pivot axis 4 . laying arm 3 is pivotably supported in an upper pivot axis 5 on the upper end 2 U of supply arm 2 . The lower (free) end 3 L of laying arm 3 is movably guided above an output conveyor 6 which has a transport direction which extends in parallel to pivot axes 4 and 5 . Lower end 3 L of the laying arm 3 is coupled to a pivot frame 7 which is guided in rails (not shown) which extend transversely across output conveyor 6 on both sides of a laying zone.
Traction ropes, toothed belts or chains 8 are attached onto pivot frame 7 and are guided over a plurality of deflection wheels 9 supported in a frame (not shown) around output conveyor 6 . One or a pair of wheels 9 , designated by reference number 9 a , is driven by a motor (not shown). So configured, pivot frame 7 can be moved back and forth transversely to output conveyor 6 . Both supply arm 2 and laying arm 3 , arm 3 being coupled with pivot frame 7 , each carry out pivoting movements.
Two endless transport belts 10 and 11 , transporting a fiber web (not shown) to be layered, are guided over supply arm 2 and laying arm 3 and around output conveyor 6 in the area of the laying zone. Transport belts 10 and 11 determine a feeding path section in which transport belts 10 and 11 are guided in parallel between a take-up site A, at which the web is supplied, and a discharge nip B at lower end 3 L of the laying arm 3 . Thus, transport belts 10 and 11 are capable of sandwiching a fiber web between them and of supporting the web. This feeding path section extends from take-up site A via a reversing roller 12 , a driven reversing roller 13 , a deflection roller 14 close to lower pivot axis 4 , over supply arm 2 and another deflection roller 15 supported at the upper pivot axis 5 , and up to discharge nip B at lower end 3 L of the laying arm 3 . (The apparatus shown in FIGS. 1 and 2 contain numerous deflecting, reversing, and drive rollers which will be specified primarily by reference number only and not by differentiating names.) Discharge nip B comprises two deflecting rollers 16 and 17 which are supported on pivot frame 7 at which lower end 3 L of laying arm 3 is articulated.
Starting at discharge nip B, the paths of transport belts 10 and 11 separate. In the example shown in FIG. 1 , web transport belt 10 extends transversely over output conveyor 6 and two deflecting rollers 18 up to a reversing roller 19 . Roller 19 is supported in a lower carriage 20 , which is positioned below output conveyor 6 . Carriage 20 can be moved on rails (not shown) transverse to output conveyor 6 . Reversing roller 19 reverses the direction of transport belt 10 . Belt 10 then runs over deflecting rollers 21 back to lower end 3 L of the laying arm 3 . At this point, belt 10 passes over another deflecting roller 22 and moves to a deflecting roller 23 located above upper pivot axis 5 . Belt 10 then moves along supply arm 2 to a deflecting roller 24 , a drive roller 25 , two further reversing rollers 26 and 27 , and a drive roller 28 located in the area of take-up site A. In this manner, the running path of web transport belt 10 is completed.
Web transport belt 11 runs from discharge nip B at lower end 3 L of laying arm 3 via deflecting rollers 18 and below output conveyor 6 to a reversing roller 29 . From reversing roller 29 , belt 11 runs back via deflecting rollers 21 A to a deflecting roller 30 mounted close to lower end 3 L of laying arm 3 , along laying arm 3 to a deflecting roller 31 located below upper pivot axis 5 , along supply arm 2 and over a deflecting roller 42 arranged close to lower pivot axis 4 to a drive roller 32 . Belt 11 then moves over a pair of reversing rollers 33 and 34 to a drive roller 35 located in the region of take-up site A. In this manner, the path of web transport belt 11 is completed.
FIG. 1 shows the cross lapper with supply arm 2 and laying arm 3 in a retracted position. Pivot frame 7 , supporting deflecting rollers 16 and 17 at discharge nip B, is located in FIG. 1 on the left side of output conveyor 6 . In this situation, lower carriage 20 supporting reversing rollers 19 and 29 is located on the right, underneath the output conveyor 6 . Comparing FIG. 1 to FIG. 2 , in which laying arm 2 and supply arm 3 are extended, it can be seen that by a displacement of pivot frame 7 to the right, lower carriage 20 is moved to the left by the same displacement. Corresponding to the additional length of transport belt 10 moved onto the upper side of the laying zone caused by this movement, lower carriage 20 has moved to the left, and at the same time provided a corresponding length of transport belt 11 , which is supported by the coupling of traction ropes, toothed belts or chains 8 to the lower carriage 20 .
When moving lower end 3 L of laying arm 3 from the position shown in FIG. 1 into the position shown in FIG. 2 , deflecting roller 16 supported on pivot frame 7 is rolling on web transport belt 11 layered by roller 16 if the speed at which web transport belt 10 is driven by its drive roller 32 is as high as the movement speed of pivot frame 7 . Since the fiber web is discharged at this speed from discharge nip B, the section of web transport belt 11 resting on the freshly layered web does not have a relative speed with respect to the web (except for the movement of output conveyor 6 transverse to the laying direction of laying arm 3 ). During this movement, transport belt 10 has a speed relative to speed at take-up site A zone which consists of the sum of the running speed of pivot frame 7 and the supply speed of transport belt 10 . The same applies to transport belts 10 and 11 for movement of pivot frame 7 in the reverse direction. Practice has shown that this relative speed between the layered fleece and transport belts 10 and 11 covering the layered fleece does not lead to problems. As mentioned above, pivot frame 7 is pivoted with respect to laying arm 3 around a horizontal axis, so that the deflecting roller ( 16 or 17 ) which is in front in the moving direction, is slightly lifted.
The section located between take-up site A and an infeed zone C at the lower end of supply arm 2 of the structure shown forms web buffering apparatus 36 . On the way back from discharge nip B to take-up site A, transport belt 10 , after leaving supply arm 2 , runs over drive roller 25 and from there into a substantially U-shaped return path portion the apex of which is formed by reversing roller 26 . Belt 10 continues over another reversing roller 27 and drive roller 28 to take-up site A.
On its way back to take-up site A, after leaving supply arm 2 , transport belt 11 also runs over drive roller 32 into substantially U-shaped return path portion, the apex of which is formed by reversing roller 33 . From there, belt 11 continues over a tensioning roller 34 and drive roller 35 which is located at the take-up site A.
Reversing rollers 26 and 33 located in the path of transport belts 10 and 11 and forming the apexes of the U-shaped return path portions, are rotatably supported in a common mounting frame 37 on which reversing roller 12 is also supported and around which the web transporting sections of transport belts 10 and 11 are guided as a pair, in juxtaposed fashion. Common mounting frame 37 is pivotally attached at the axis of reversing roller 12 at a frame-shaped link 38 , which is only schematically shown in the drawing with a dash-dotted line. Link 38 is suspended like a pendulum in a pivot bearing 41 in machine stand M (shown in dotted line format only in FIG. 1 ) of the cross lapper.
Tensioning roller 34 is mounted on the piston of a hydraulic cylinder 39 attached to machine stand M. The force exerted by hydraulic cylinder 39 onto tensioning roller 34 tensions transport belt 11 . The tension is transferred over reversing roller 33 and through common mounting frame 37 , which acts as a two-armed lever by pivoting around the axis of reversing roller 12 . The tension is further transferred over reversing roller 26 carried by common mounting frame 37 to the returning section of transport belt 10 . Thus, both web transport belts 10 and 11 are tensioned by single hydraulic cylinder 39 .
On their way over the arms 2 and 3 the transport belts 10 and 11 run over several guide rollers 40 supported on the feeding and laying arms 2 and 3 , some of the guide rollers alternatingly contacting on the one and the other side of the paired transport belt section to prevent fluttering of the transport belts on the arms 2 and 3 .
Various operating states will now be described. As long as drive rollers 13 , 25 , 28 , 32 and 35 have identical circumferential speeds, common mounting frame 37 stays in the position shown in FIG. 1 . If the circumferential speed of drive roller 13 becomes higher than that of the other drive rollers, drive roller 13 pulls common mounting frame 37 , through paired transport belts 10 and 11 and reversing roller 12 , to the left in FIG. 1 , causing the length of the web transporting sections of transport belts 10 and 11 to shorten. At the same time, the length of the returning sections of transport belts 10 and 11 increases since reversing rollers 26 and 33 are also moved to the left. Positions of rollers 12 , 26 and 33 moved to the left are shown in dotted lines in the drawing by reference numbers 12 ′, 26 ′ and 33 ′, respectively.
If, however, the drive speed of drive roller 13 becomes lower than the speed of the other drive rollers, common mounting frame 37 moves to the right (in FIG. 1 ) so that reversing rollers 12 , 36 and 33 reach the positions shown in FIG. 1 by reference numbers 12 ″, 26 ″ and 33 ″, respectively. Since the displacement of the reversing rollers 12 , 26 and 33 takes place in essentially equal amounts, transport belts 10 and 11 remain tensioned.
By the aid of the movement of common mounting frame 37 , the length of transport belts 10 and 11 between take-up site A and discharge nip B can be varied. Thus, it is possible to temporarily change the speed of the web discharge at discharge nip B compared to the web infeed speed at take-up site A. This change is required for cross lapper 1 , since the speed at which discharge nip B, i.e., the pivot frame 7 , moves over output conveyor 6 , cannot be constant, since in the area of the movement reversal points of laying arm 3 , its speed must be reduced by braking to zero and then accelerated in the opposite direction after the reversal of the movement. If during these braking and accelerating phases transport belts 10 and 11 continue to discharge web through discharge nip B, web thickening would result in the marginal area of the fiber web by the cross lapper, and such variations must be prevented. Thus it is necessary to vary the speed at which the web is discharged by transport belts 10 and 11 , adapting to the speed at which pivot frame 7 moves over output conveyor 6 . This variation of the discharge speed of the web from discharge nip B can be managed by suitable control of the speed of drive rollers 13 , 25 and 32 with respect to the speed of drive rollers 28 and 35 , wherein frame 37 carries out a substantially oscillating movement around pivot bearing 41 . This oscillating movement moves reversing rollers 12 , 26 and 33 between positions 12 ′, 26 ′ and 33 ′ on the one hand and positions 12 ″, 26 ″ and 33 ″ on the other hand, and thereby cyclically changes the buffered web volume.
The structure of web buffering apparatus 36 shown can also fulfill another task. For this purpose another movement component of common mounting frame 37 will now be explained with reference to FIGS. 1 and 2 . FIG. 2 shows cross lapper 1 with supply arm 2 and laying arm 3 in an extended position. It can readily be seen in FIG. 2 that the wrapping angles of transport belts 10 and 11 on deflecting rollers 15 , 23 and 31 , which are arranged in arms 2 and 3 in the region of upper pivot axis 5 , and on deflecting rollers 14 , 24 and 42 , which are arranged in the region of lower pivot axis 4 of supply arm 2 , vary from the wrapping angles shown in FIG. 1 . While the change of the wrapping angles of the paired web transport belt sections and also the change of the wrapping angles at deflecting rollers 23 and 31 do not have opposite influences on web transport belts 10 and 11 as far the return sections thereof are concerned, the wrapping angle of the return section of belt 10 on deflecting roller 24 in FIG. 2 is smaller with respect to that in FIG. 1 , whereas the wrapping angle of the returning section of belt 11 on deflecting roller 42 is greater than in FIG. 1 . Such wrapping angles of web transport belts 10 and 11 therefore change in opposite directions. Transport belt 10 requires an increase in the running path length of its return section, while transport belt 11 requires a decrease in the running path length of its return section. Both can be achieved by the aid of tensioning roller 34 , influenced by the hydraulic cylinder 39 , which, in FIG. 2 presses the tensioning roller 34 to the right, resulting in common mounting frame 37 being pivoted from its position shown in FIG. 1 in counter-clockwise direction on link 38 into the position shown in FIG. 2 . The length of the returning section of transport belt 11 is decreased, and at the same time, the length of the returning section of transport belt 10 is increased.
It is obvious that the movement of common mounting frame 37 around pivot bearing 41 of link 38 and the pivoting movement of common mounting frame 37 on link 38 around the axis of roller 12 reversing paired web transport belts 10 and 11 , superimpose on one another during operation, since the compensation of the speed difference of the transport belts 10 and 11 at discharge nip B and take-up site A and the compensation of the change of the roller wrapping angles in opposite directions must take place simultaneously.
As an example of a practical embodiment of the invention, the laying width is 3,500 mm. The length of arms 2 and 3 between deflecting roller 31 and the ends of the arms is 2,800 mm each. Transport belts 2 and 3 each have a length of 21,500 mm. The movement path of lower end 3 L of laying arm 3 of camel back cross lapper 1 is 4,000 mm. In the retracted condition of arms 2 and 3 ( FIG. 1 ), arms 2 and 3 include an angle of approximately 27°, whereas in the extended position ( FIG. 2 ), arms 2 and 3 include an angle of approximately 133°. The difference in the yielding of transport belts 10 and 11 which is caused by the change of the wrapping angles on deflecting rollers 24 and 42 (in turn caused by the different arm positions during extension), is compensated by an adjustment of approximately 20 mm on tensioning roller 34 by hydraulic cylinder 39 . Frame-like link 38 , at which common mounting frame 37 is suspended, has an effective length (pendulum length) of 1,400 mm, whereas the distance of reversing rollers 26 and 33 on the common mounting frame 37 from reversing roller 12 common to the transport belts is 520 mm each. For accommodating web buffering apparatus 36 , a space of approximately 2,100 mm in front of the camel back cross lapper 1 and a height of approximately 1,740 mm is required, including link arrangement 31 .
A variety of alternatives are possible and are obvious to the person skilled in the art of the present invention. For instance, reversing roller 12 supported on common mounting frame 37 may serve as a drive roller, whereas roller 13 may serve as an idling reversing roller. Furthermore, reversing rollers 26 and 33 supported on common mounting frame 37 may be drive rollers, with rollers 25 and 32 serving as idling deflecting rollers. Common mounting frame 37 could be pivotally supported in a movable carriage instead of being suspended on link 38 . Furthermore, cross lapper 1 could have four or more hinged arms in order to achieve a larger laying width without increasing height, such hinged arms being arranged and movable in accordion-like fashion. In such case, the movement of the arms would be coordinated with movement of the laying arm. In an arrangement of this type, transport belts 10 and 11 would be guided in pairs over all of the arms articulated to one another so that the fiber web is permanently sandwiched between two tightly contacting transport belts across its entire feeding path.
The integration of web buffering apparatus, web guidance over the supply and laying arms, and the covering of the layered web on the output conveyor by using a single pair of transport belts offers excellent advantages over the prior art not only in view of the cost of the apparatus but also in view of the quality of the product produced. The fiber web to be layered for producing a fleece is held in this integrated device in uninterrupted fashion between the web transport belts from the take-up site to the discharge nip. The fiber web is free from mechanical loads caused by free suspension, by tensioning, and by transfer from one transport belt to the other. Such freedom from mechanical loads is not available in cross lappers which work with several movable carriages. This careful and conservative treatment of the fiber web is continued after leaving the discharge nip, since the web is accompanied by one of the transport belts, namely the transport belt that covers it directly after leaving the discharge nip. The web rests on a support and is free from exposure to unfavorable aerodynamic forces as well.
While the principles of the invention have been shown and described in connection with specific embodiments, it is to be understood that such embodiments are by way of example and are not limiting.
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In a camel back cross lapper, a fiber web to be layered to form a fleece is guided from an infeed zone until its discharge in a layering zone in sandwiched manner between two transport belts extending over the arms of the cross lapper. The transport belts are extended over a layering zone on an output conveyor to cover the web freshly deposited onto the output conveyor to avoid the web from being affected by harmful aerodynamic effects created by the movement of the layering arm of the cross lapper. In an embodiment, a web buffer is combined with the cross lapper such manner that the transport belts extend through web buffer.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on and hereby claims priority to German Application No. 101 61 321.0 filed on Dec. 13, 2001, the contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a method for updating electronically modifiable components of an automation appliance for the purpose of optimizing the execution of a control program on the automation appliance.
[0004] 2. Description of the Related Art
[0005] “Updating”, the loading of a current or later version of a piece of software on a target appliance, e.g. a “personal computer”, is a known concept. This involves the software being installed on the target appliance and any earlier version of the software already present on the target appliance being replaced. When updating a complex piece of software, for example when updating the “operating system”, a large number of individual software components are installed on the target appliance, some of which, e.g. “device drivers”, are intended to actuate the hardware connected to the target appliance (screen, printer, etc.). After the update, the user of the target appliance has an updated piece of software available. Often, however, the individual user does not require the full performance scope of a software package, which means that storage space is disadvantageously taken up by software components which the user does not use. In addition, increased performance diversity in individual software components is frequently to the detriment of the speed at which such software components process the instructions intended for them. One example which may be used in this context is a device driver for actuating a printer: in a first version, the device driver is suitable only for actuating a few printers in a particular series from a particular manufacturer. With every new printer from this manufacturer in this series, the device driver is updated in order to beable to make optimum use of any newly added functions of the latest printers as well. This firstly increases the scope of the device driver and the storage space it takes up following installation on a target appliance. In addition, however, the processing speed is unfavorably affected, for example because performance of individual functions of the device driver increasingly requires case distinctions to be made in order to achieve the best conditioning of the data stream for the respective printer which is connected. The result of this is that, for a user installing an update, for example for his operating system, which also includes device drivers of the type described above, the new software can entail losses of performance if the target appliance itself and appliances which are connected thereto remain unchanged.
SUMMARY OF THE INVENTION
[0006] The invention is based on an object of specifying a method for updating electronically modifiable components of an automation appliance for the purpose of optimizing the execution of a control program on the automation appliance where such drawbacks can be avoided. In this case, electronically modifiable components are, by way of example, the device drivers, “library functions”, particularly those which can be reloaded at the time of execution, functional modules etc. The term electronically modifiable components thus covers software components of any kind which can be installed on a target appliance and can be uninstalled again at a later time or can be replaced by one or more other software components. Such control components have the advantage that their software or firmware can be replaced while the hardware remains the same. This becomes necessary in the case of any error correction required in this software and also for replacing or reloading technological functions and modules.
[0007] An update manager is provided which uses information about the control program and about dependencies between each electronically modifiable component and a piece of hardware in the automation appliance, on the one hand, and also between the electronically modifiable components themselves, on the other, to ascertain that combination of electronically modifiable components which allows optimum execution of the control program.
[0008] In this context, the invention is based on the insight that although the control program can be executed on the automation appliance as intended with a large number of combinations of electronically modifiable components, just one or a few combinations permit optimum execution of the control program, for example with regard to processing speed. The update manager allows a large amount of information about the control program, about the hardware in the automation appliance and also about the electronically modifiable components themselves to be used to ascertain such combinations.
[0009] The advantage of the invention is that a user is supported in the installation of a control program on an automation appliance by virtue of one or more optimum combinations of electronically modifiable components being automatically presented to him. The user can install an optimum combination on the automation appliance. If appropriate, he can even select from various “optimum combinations” if the update manager has ascertained, by way of example, a first optimum combination with optimization in respect of the storage requirement, a second optimum combination with optimization in respect of the processing speed, and a third optimum combination with optimization in respect of a maximum achievable data throughput for a communication medium actuated by the control program, such as a local field bus. A configuration with a plurality of optimum combinations may arise if, by way of example, a first component, which definitively affects the processing speed, is not compatible with a second component, which definitively affects the data throughput on the field bus. A combination of electronically modifiable components which includes these two components cannot be used to execute the control program, since the two components are not compatible with one another, of course. There thus remains just the selection between a combination of electronically modifiable components with the first component and a combination of electronically modifiable components with the second component.
[0010] If the update manager forwards the ascertained combination of electronically modifiable components to a loading program in the automation appliance which installs each component on the automation appliance, then the method can proceed—barring error or selection situations—without any intervention by a user. This makes optimization in line with the invention possible over long distances as well, for example if the programming appliance and the automation appliance are communicatively connected by the Internet.
[0011] The control program is used by a user to prescribe information. Advantageously, this information is automatically extended by the update manager by virtue of the control program being analyzed in relation to requirements which are implicitly or explicitly contained therein. Each requirement recognized, e.g. the requirement for use of a particular service in the operating system, extends the information about the control program.
[0012] Advantageously, the update manager accesses a first database, from which it is possible to pick up information about the available electronically modifiable components. If analysis of the control program ascertains that a particular operating system service is used and this operating system service is available in a plurality of versions, then it is possible to pick up from the first database how the individual versions of the operating system service differ for this operating system service, for example. This means that the update manager can automatically ascertain which component from a list of components which are each basically suitable can be expected to result in particularly fast processing or particularly efficient use of the available storage space.
[0013] Another advantage is that the update manager accesses a second database, from which it is possible to pick up information about the hardware in the automation appliance. The user's information about the control program (see above) also includes information about the target hardware, i.e. an indication of the type or of the performance class of the automation appliance on which the control program is intended to be executed. The second database stores information relating to the hardware in a large number of automation appliances. The information about the target hardware can be used for specifically retrieving the necessary hardware information from this second database. The hardware information is necessary so as to be automatically able to ascertain, by way of example, which components are suitable for execution on the specific hardware in the automation appliance.
[0014] Another advantage is that the update manager accesses a third database, from which it is possible to pick up information about the combinability and/or compatibility of individual electronically modifiable components. From a large number of components which are suitable for satisfying particular requirements of the control program, the components which may be considered for further selection are those which are suitable for execution on the specific hardware in the automation appliance. Among the components which thus remain, consideration for further selection can be given to those which can be combined and/or are compatible with further components which are necessary for satisfying other requirements of the control program. Access to the information in the third database allows this selection to be made automatically by the automation manager.
[0015] If one or each electronically modifiable component which is already installed on the automation appliance but which are not part of the ascertained combination of electronically modifiable components for the purpose of optimizing the execution of the control program is uninstalled on the automation appliance, the functionality of the automation appliance can advantageously be matched exactly to the needs of the control program, and any unnecessary functionality on the automation appliance can be erased.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] These and other objects and advantages of the present invention will become more apparent and more readily appreciated from the following description of an exemplary embodiment of the invention, taken in conjunction with the accompanying drawings of which:
[0017] FIG. 1 is a block diagram of a development environment with a programming appliance and an automation appliance, and
[0018] FIG. 2 is a block diagram illustrating functionality of the update manager.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout.
[0020] FIG. 1 shows a programming appliance 1 with a control program 2 . The control program 2 is stored in a memory (not shown) in the programming appliance 1 in the usual manner. The control program 2 is written or modified on the programming appliance 1 . The finished control program 2 is intended to be executed on an automation appliance 3 . The control program 2 is transferred from the memory in the programming appliance 1 to a memory (not shown) in the automation appliance 3 via a communication link 4 , e.g. a field bus 4 .
[0021] To execute the control program 2 on the automation appliance 3 , further software components 5 , 6 , 7 are required. A first group 5 of software components includes a “module” 5 which provides a particular functionality in the manner of a “macro” or of a “library function”. Execution of the control program 2 may require a large number of modules 5 , e.g. modules 5 for typical basic functions, such as logic functions, or modules 5 for technological functions, such as control functions. A second group 6 of software components includes an operating system function 6 which, by way of example, acts as an interface to the hardware in the automation appliance 3 or is intended for priority level control or for execution level control. Execution of the control program 2 may require a large number of operating system functions 6 . A third group 7 of software components includes a “hardware configuration unit” 7 for configuring and/or diagnosing sensors or actuators connected to the automation appliance 3 for the purpose of controlling and/or monitoring a technical process (not shown). Depending on the nature and scope of the process peripheral area connected to the automation appliance 3 , a large number of hardware configuration services 7 may be required for operating the control program 2 .
[0022] Each module 5 , each operating system function 6 and each hardware configuration service 7 is an electronically modifiable component 5 , 6 , 7 . Just as any component 5 , 6 , 7 can be loaded into the memory in the automation appliance 3 and hence is installed and can be used on the automation appliance 3 , it is also possible for any component 5 , 6 , 7 to be uninstalled again and to be erased from the memory in the automation appliance 3 .
[0023] To optimize execution of the control program 2 on the automation appliance 3 in the course of updating such electronically modifiable components 5 , 6 , 7 of the automation appliance 3 , an update manager 8 is provided. The update manager 8 uses information about the control program 2 and also about dependencies between each electronically modifiable component 5 , 6 , 7 and the hardware in the automation appliance 3 and also between the electronically modifiable components 5 , 6 , 7 themselves for the purpose of automatically ascertaining that combination of electronically modifiable components 5 , 6 , 7 which allows optimum execution of the control program 2 .
[0024] The ascertained combination of electronically modifiable components 5 , 6 , 7 , the optimum combination 5 , 6 , 7 below, is transmitted to a loading program 9 in the automation appliance 3 which installs each component 5 , 6 , 7 of the optimum combination on the automation appliance 3 .
[0025] A communication link 10 , e.g. a “Cellbus” 10 (Ethernet), provides the update manager 8 with access to, by way of example, a further programming appliance 11 and to the latter's memory 12 and/or to a data server 13 and installation data held on the latter, e.g. on a “compact disc” 14 (CD), and/or to the “Internet” 15 .
[0026] From each of these data sources 12 , 14 , 15 , the update manager 8 can obtain individual or all electronically modifiable components 5 , 6 , 7 . This is done, by way of example, using standardized communication protocols, such as FTP (File Transfer Protocol) or the like.
[0027] FIG. 2 shows a schematic illustration of the functionality of the update manager 8 . The update manager 8 includes an analysis unit 20 and an adaptation unit 21 . The analysis unit 20 accesses criteria and parameters 22 connected with the users and also accesses features 23 of the control program 2 ( FIG. 1 ). In addition, the analysis unit 20 has access to a first database 24 and, in this context, obtains information about the available electronically modifiable components 5 , 6 , 7 ( FIG. 1 ), the “domain knowledge”. The information compiled and possibly processed by the analysis unit 20 is forwarded to the adaptation unit 21 . The adaptation unit 21 is intended to adapt the control program 2 to the specific automation appliance 3 ( FIG. 1 ). To this end, the adaptation unit 21 has access to a second database 25 containing information relating to the hardware and relating to the operating system of possible target appliances. From this second database 25 , the adaptation unit 21 uses data 26 relating to the automation appliance 3 actually used as the target appliance in order to pick up information about the latter's hardware and/or the latter's operating system. If it is not possible to adapt the control program 2 for the automation appliance 3 on the basis of the prescribed data 22 , 23 , 26 , corresponding advice 27 , e.g. an error message 27 , is output for the user.
[0028] The information compiled and possibly processed by the analysis unit 20 and the adaptation unit 21 is forwarded to a combination unit 28 which has access to a third database 29 and picks up therefrom information about the combinability and/or compatibility of individual electronically modifiable components 5 , 6 , 7 . The combination unit 28 uses this information to generate a list of required electronically modifiable components 5 , 6 , 7 which allows optimum execution of the control program 2 . In addition, the ascertained combination of electronically modifiable components 5 , 6 , 7 can be aligned in the course of a dialog 30 with a user, in order to eliminate any errors which have occurred, to lift or explicitly permit restrictions to the compatibility, or to perform optimization in terms of freedom from reaction. The list of the optimum combination of electronically modifiable components 6 , 7 , 8 which the combination unit 28 has generated is transmitted to a transfer unit 31 which obtains the actual data for each electronically modifiable component 6 , 7 , 8 by accessing data sources 12 , 14 , 15 ( FIG. 1 ), e.g. the Internet 15 . Finally, the transfer unit 31 transfers the selected combination of electronically modifiable components 6 , 7 , 8 to the loading program 9 ( FIG. 1 ) in the automation appliance 3 , which installs each component 5 , 6 , 7 of the optimum combination on the automation appliance 3 .
[0029] The invention can thus be presented briefly as a method for updating electronically modifiable components 5 , 6 , 7 of an automation appliance 3 for the purpose of optimizing the execution of a control program 2 on the automation appliance 3 is specified in which an update manager 8 uses information about the control program 2 and also about dependencies between each electronically modifiable component 5 , 6 , 7 and a piece of hardware in the automation appliance 3 and also between the electronically modifiable components 5 , 6 , 7 themselves to ascertain that combination of electronically modifiable components 5 , 6 , 7 which allows optimum execution of the control program 2 .
[0030] The invention has been described in detail with particular reference to preferred embodiments thereof and examples, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
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Electronically modifiable components of an automation device are updated to optimize execution of a control program in the automation device. Based on information about the control program and about interdependencies between each electronically modifiable component and the hardware of the automation device as well as among the electronically modifiable components, an update manager determines the combination of electronically modifiable components with which the control program can be executed in an optimal manner.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to a selective collecting system of washingly treated articles, for example rolled towels which are regenerated by washing and collected for repeat use.
The term rolled towels as used herein means towels to be used in the form of a roll of towel at lavatories at home, offices, restaurants and hotels as rental goods.
(2) Description of the Prior Art
Conventionally, washingly treated articles have not been inspected for damage after the washing treatment was performed. Therefore, such treated articles have automatically been circulated as articles to be re-used, even if damaged through use or washing. For example, rental rolled towels which have been repeatedly used have been recirculated on the market pierced with holes or having frayed edges. Therefore, confidence of the users on such articles has considerably been lowered.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a system of selecting articles according to their damage as to holes or tears resulting from use or washing, thereby collecting the articles having a desired quality, in an easy and rapid manner.
In order to achieve the object above-mentioned, a selective collecting system of washingly treated articles according to the present invention comprises a detector for detecting damage of treated articles after washing treatment, a selective collecting device for selectively collecting the treated articles and a control mechanism for automatically selecting the selective collecting position in the selective collecting device according to a result detected by the detector.
According to the present invention, damage of treated articles may be detected after washing treatment and such articles are selectively collected based on such detection. Thus, after washing treatment and prior to the circulation of such articles as goods for re-use, their damage may securely be detected regardless whether such damage is resulted from the use or washing, and articles having a desired quality may be collected readily and speedily.
Accordingly, the entire working efficiency may be improved. In the particular case where such articles are rental rolled towels to be repeatedly used, such towels that are unexpectedly pierced with holes are prevented from being circulated on the market thereby lowering public confidence. Thus, the present invention may provide a great practical effect.
It is another object of the present invention to prevent, in sterilization of such towels above-mentioned, sticking of stains to such towels due to dew condensation and deterioration of the towel fibers as a result of conventional sterilization with the use of chloric type chemicals. Thus, good quality towels capable of being repeatedly used may be collected.
Other objects and advantages of the present invention will be apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be further described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a general flow sheet of a selective collecting system of washingly treated articles in accordance with the present invention which is applied to the continuous washing of rolled towels;
FIG. 2 is an enlarged side view of main portions of the system;
FIG. 3 is a partially developed plan view of the system, particulary showing a control device; and
FIG. 4 is a reference graph.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A rolled towel continuous washing system for efficiently washing a plurality of rolled towels comprises a storage tank 1 in which used towels A collected in the wound state are stored, a sewing machine 2 for connecting the longitudinal ends of towels A taken out of the storage tank 1 while being unwound thereby forming such towels into a band shape, a conveyor system 3 through which band-like towels are continuously conveyed to an inlet-side accumulator unit 4, an immersion tank 5, washing tanks 6, rinsing tanks 7, a dehydrating means 9 having a pair of wringing rollers 8, a sterilizing device 10, a drying device 11 and an outlet-side accumulator unit 12, and a selective collecting device 13 by which towels A are windingly collected one by one.
A washing solution of a surface active agent mixed with a supplementary agent is supplied to and stored in the immersion tank 5 with its concentration and temperature controlled.
The sterilizing device 10 is constructed so as to sterilize band-like towels with steam. Thus, in the continuous washing system according to the present invention, no chloric type chemicals are used, thereby greatly reducing deterioration of the towel fibers, which may otherwise result from washing and sterilization.
A detector device 14 comprising a projector means 14a and a light receiving means 14b is disposed between the storage tank 1 and the sewing machine 2. This detector device 14 is constructed so as to detect the ends of towels A, based on the principle that the amount of received light is increased when the ends of towels A pass through the detector device 14. The detector device 14 is interlocked with a drive roller unit 15 for feeding band-like towels to the inlet-side accumulator unit 4. When the ends of towels are detected, towel transfer is automatically stopped with the ends of towels transferred to the position where towels are connected to each other by the sewing machine 2.
At the inlet-side accumulator unit 4, band-like towels are adapted to be fed to and stored, in a folded state, in a J-shape container 16 having a lateral side made of acryl plate such that the inside therein may be visible. Thus, intermittent connection of towels A by the sewing machine may be performed without injuring the continuity of the succeeding treatments.
The container 16 has a weight detector means (not shown) with which a buzzer is interlocked, so that the sewing machine operator may be informed of whether a detected weight exceeds or is less than a predetermined weight range by the sound of the buzzer. Thus, the operator's attention may be captured so that he can interrupt the towel connecting operation when the wound stress is increased, and increase the speed of the towel connecting operation when the wound stress is diminished. Accordingly, the amount of towel storage may be maintained within a predetermined range so that succeeding continuous operations may efficiently be performed.
The immersion tank 5 has at the feed portion thereof a beater 17 to feed band-like towels, as folded, by a predetermined distance (for example 20 to 30 cm) in the longitudinal direction of the towel band. The immersion tank 5 also has a pair of upper and lower synchronous conveyors 18, between which the band-like towels are holdingly transferred.
In the immersion tank 5, a heated washing solution of a surface active agent mixed with a supplementary agent mentioned earlier is circulated by convection with a pump and a shower means such that the washing solution comes in full contact with both surfaces of the band-like towels.
Two washing tanks 6 are disposed in series and each tank 6 has two roller-shaped brushes 19 rotating in the direction opposite to the towel transfer direction so as to come into contact with both surfaces of the band-like towels. Such contact of the brushes impregnate the towels with the washing solution in the immersion tank 5 thereby permitting removal of stains or spots on the towels. The brushes 19 are constructed such that their distance from the band-like towels is adjustable. Thus, contact pressure of the brushes 19 may be adjusted and wear of the brushes 19 may be absorbed, thereby providing a predetermined contact pressure.
Two rinsing tanks 7 are disposed in series and each tank 7 has two freely rotatable punching drums 20 disposed such that both surfaces of the band-like towels come in contact with the peripheries of the punching drums 20. The rinsing tanks 7 also have sprays 21 to sprayingly supply water or warm water to the band-like towels in contact with the punching drums 20. Thus, the washing solution, and spots or stains washingly removed or ready to be removed may be removed and absorbed to the inside of the punching drums 20 from the band-like towels.
Provision is made such that most of water or warm water used in the rinsing tanks 7 may be recirculated through filters and a portion of such water may be supplied to the immersion tank 5, so that water saving may be realized as much as possible.
The sterilizing device 10 has a steam generator 24 comprising a water reservoir 22 and heating pipes 23 therein through which steam from a boiler B passes. A sterilizing chamber S is formed at the upper portion of the sterilizing device 10 and is covered by a peripheral wall 25. The bandlike towels are continuously carried in and out from the sterilizing chamber S in a zigzag line. The band-like towels stay, for a predetermined period of time (for example, 1 to 60 minutes), in the sterilizing chamber S filled with steam generated by the steam generator 24, thereby annihilating bacilli and, more particularly Escherichia coli.
The peripheral wall 25 is a double wall, and between the opposite surfaces thereof there is formed a space S 1 for supplying heated steam from the boiler B. In order to avoid dew formation when steam in contact with the peripheral wall 25 is cooled, a heating device 26 is disposed for heating the peripheral wall 25.
A suction blower 27 is provided for collecting steam discharged from towel inlet port 28 and outlet port 29 disposed at the sterilizing chamber S. Supply lines R are disposed for supplying steam directly to the inside of the sterilizing chamber S at the early stage when the steam generator 24 is initially started.
In the sterilizing chamber S, a detector means 30 is disposed for detecting a temperature in the sterilizing chamber S. Adapted to be supplied to and compared at a comparator 32 are a detection signal from the detector means 30 and a signal from a temperature setting device 31 to set the temperature and humidity of steam in the sterilizing chamber S in the range from 98° C. to 102° C. and 98% or more, respectively. According to a result of such comparison, a command signal is adapted to be supplied to an operating circuit 33. In response to the command signal from the operating circuit 33, an electromagnetic valve V disposed in the supply line from the boiler B in the steam generator 24 is operated. Thus, a control device 34 is constructed to automatically adjust the amount of steam to be generated by the steam generator 24 such that the temperature of steam in the sterilizing chamber S is maintained at the range from 98° C. to 102° C. and the humidity of steam at 98% or more.
In the embodiment discussed hereinbefore, the temperature is preset by the setting device 31 such that the temperature and humidity of steam in the sterilizing chamber S are maintained at the range from 98° C. to 102° C. and 98% or more, respectively, whereby sterilization is performed in a satisfactory manner with high heat conduction efficiency. However, even though such temperature and humidity are lowered dependent on the degree of towel stains, it is still possible to achieve a predetermined sterilizing effect, as discussed later. Namely, a predetermined sterilizing effect may be obtained with the temperature and humidity at least maintained at 70° C. and 45%, respectively.
With respect to the steam generator 24, various modifications may be possible. For example, steam independently generated may be supplied to the inside of the sterilizing chamber S, or Nichrome wires instead of heated steam may be disposed in the heating pipes 23.
In the embodiment discussed hereinbefore, steam is adapted to be discharged from the sterilizing chamber S to the outside through the inlet and outlet ports 28 and 29 when the sterilizing chamber S is fully filled with steam, and the internal atmospheric pressure may therefore be regarded as 1. FIG. 4 shows the relationship between the saturated steam pressure and the temperature, and also shows the humidity at each temperature when saturated steam was overheated.
The drying device 11 comprises eleven siphon-type steam cylinders 35 in two rows, each cylinder having a width at least three times the width of a towel. The band-like towels are adapted to be dried by passing through these steam cylinders 35 three times.
The outlet-side accumulator unit 12 is constructed similarly as the inlet-side accumulator unit 4. The continuously conveyed band-like towels are adapted to be supplied to the starting end of the accumulator unit 12 and then stored in the container such that the succeeding intermittent operation at the selectively collecting device 13 may readily be performed.
The selective collecting device 13 comprises a winding device 36 for winding up towels one by one with the end portions of towels wound therearound, and a distributing device 37 for receiving and distributing the wound towels. The distributing device 37 is drivingly rotatable around the longitudinal axis Q through a drive mechanism 38.
Disposed between the outlet-side accumulator unit 12 and the winding device 36 is a first detector 41 comprising a projecting light source 39 and a light receiving means 40 which are disposed above and under the conveyed band-like towels, respectively. Also disposed between the outlet-side accumulator unit 12 and the winding device 36 is a second detector 43 for which the light source 39 of the first detector 41 also serves as light source, the second detector 43 having a light receiving means 42 adapted to receive a light from the light source 39 reflected on the band-like towels.
Signals from the first and second detectors 41 and 43, and signals from setting devices 44 and 45 are supplied to and compared at comparators 46 and 47. Based on the result of such comparison, signals are supplied to a selecting circuit 48, where signals from the comparators 46 and 47 are then compared and selected. According to such comparison and selection, a command signal is supplied to an operating circuit 49, by which the drive mechanism 38 is operated to change the rotary angle thereof.
With such arrangement, according to variations of the amount of transmitted light, the first detector 41 may detect damaged towels such as rents and frayed edges, and according to variations of the amount of reflected light, the second detector 43 may detect the washing state of towels as to stains, mold or spots. Dependent on such damage and washing state detected, the rotary angle of the distributing device 37 or the towel collecting position may be automatically changed. Thus, a control device 50 is constructed so as to classify towels, readily and rapidly, into good quality towels capable of being re-used, damaged towels requiring repairs and insufficiently washed towels requiring re-washing.
The description hereinafter will discuss how rolled towels are transferred to the distributing device 37 from the winding device 36.
As shown in FIG. 2, interlocking with the winding device 36 is a detector means H adapted to detect the ends of towels A based on the fact that the towel connected portions P have a thickness greater than other portions. When the ends of towels are detected, towel transfer is automatically stopped with the towel ends conveyed to the position opposite to the winding device 36. Subsequent to such towel transfer stop, the machine-sewed thread is manually removed to release the connection of towels. Thereafter, by turning a start switch to ON, a cylinder 51 is operated to convey wound towels to the distributing device 37, simultaneously with the operation of the control device 50.
Furthermore, the winding device 36 has a third detector 52 for detecting the length of a rolled towel according to the number of rotations thereof, and a forth detector 53 to come in contact with the outer peripheral surface of the rolled towel A and to detect the diameter of the rolled towel A according to the swing angle thereof. Signals from the third and forth detectors 52 and 53 are adapted to be supplied to the operating circuit 49. Thus, the incorporation of the third and forth detectors 52 and 53 in the control device 50 permits a highly accurate quality control to be realized; namely, if towels do not comply with standard requirements, even though they are satisfactory in view of the damage and washing state, such towels are excluded as defective.
One example of quality control performed by the control device 50 is shown in the following table.
______________________________________Item to beinspected Inspection standard Instruction______________________________________Strong stain 1.0cm × 1.0cm or more Re-WashingStrong rust 1.5cm × 1.5cm or more Re-WashingLight rust/spot 2.5cm × 2.5cm or more Re-WashingEdge fraying 1.0cm W × 1.5cm L or more RepairRent 1.0cm W × 1.0cm L or more RepairRolled towel dia. 2.0 cm or more DefectiveTowel length 30 m or less Defective______________________________________
It is to be noted that application of the present invention is not limited to selective collection of washingly treated towels, but the present invention may also be applied to sheets, and such articles are generally defined as washingly treated articles.
In the embodiment discussed hereinabove, a sterilizing means with the use of ultraviolet rays may be disposed between the sterilizing device 10 and the drying device 11.
Stains of towels are chiefly dirt from the hands (protein, sebum horny substance), and also include red iron mold, blood, lipstick, coloring matter, soy sauce, spots resulted from the propagation of bacilli (mainly black spots by the Aspergillus and green spots by the penicillus genus) or others.
TABLE 1__________________________________________________________________________Comparison of Treating Conditions and Effect According to the System ofthe Present Invention Stain 1 Stain 2 Stain 3Classification Un- Un- Un-of stain treated 1 2 3 4 5 treated 1 2 3 4 treated 1 2 3 4 5__________________________________________________________________________ConditionTemperature 70 70 70 80 90 90 95 98 90 95 98 98 98 102Humidity (%) 45 45 45 60 70 60 70 80 0 60 98 98 98 5Period of 30 40 60 20 20 5 20 5 20 40 5 1 2 10stay time(min.)EffectNumber of 174 165 158 125 122 167 120 167 103 98 145 150 150 82washing timesTensile strength 4.8 4.6 4.2 3.3 3.3 4.6 3.2 4.6 2.5 2.4 3.9 4.0 4.0 2.0(kg/cm)BacilliEscherichia coli 320 0 0 0 0 0 500 0 0 0 0 1780 0 0 0 0 0(number/cm.sup.2)General bacilli 72000 185 192 98 82 38 230000 168 42 122 720 520000 172 0 115 35 535(number/cm.sup.2)General X X X X X XJudgment__________________________________________________________________________ Notes: X: Defective below standard requirements Average although standard requirements are met Good with standard requirements met The overall judgment has been made taking into account not only the numbe of bacilli but also deterioration of the towel fibers based on tensile strength.
These stains may be roughly classified into light stains, light spots, and general contamination (hereinafter referred to as Stain 1), strong stains, light mold and partial strong spots (hereinafter referred to as Stain 2) and stains essentially comprising mold (hereinafter referred to as Stain 3).
The results of tests conducted per each classification are shown in the following table:
It has found from the tests above-mentioned that, when the temperature and the himidity were set to, for example 70° C. and 45% respectively in order to keep down the sterilizing efficiency to the necessary minimum, it was required to adjust the period of stay time but a desired sterilizing effect was still obtained with the period of stay time being 60 minutes or more, as shown in the Table. However, when the temperature or the humidity was set to less than 70° C. or 45%, a desired sterilizing effect was not obtained even though the period of stay time was much extended.
The following table shows a comparison in strength and sterilization between conventional systems in which sodium hypochlorite and high test bleaching power were used as disinfectant, respectively, with effective chlorine concentration of 200 ppm, and the sterilization system in accordance with the present invention in which steam was used as disinfectant.
TABLE 2______________________________________ Number of Washing Number of (Sterilizing) Tensile GeneralSterilizing Method times Strength Bacilli______________________________________Sodium hypochlorite 63 1.4 kg/cm 400/cm.sup.2High test bleaching 71 1.6 720powderSteam(2 minute contact) 150 4.0 35______________________________________
For the tests above-mentioned, conventional washing was performed in such a way that towels of a predetermined amount are subjected to washer washing, i.e. washing (one time), sterilization (one time) and rinsing (three times), and are then dehydrated by a centrifugal filter, and then dried with apparatus of the type for drying and winding sheets. In such conventional washing, a solution having an effective chlorine concentration of 200 ppm was used as disinfectant.
From Table 1, it has found that the sterilizing system in accordance with the present invention provides a very high sterilizing effect.
From Table 2, it has found that, in spite of the number of washing times being more than twice, towels washed by the system in accordance with the present invention have two times the tensile strength and exhibit extremely less fiber deterioration with excellent sterilization.
As apparent from Table 1, tensile strength of towels Varies with the humidity. Namely, the provision of a predetermined humidity may not only improve sterilizing effect, but also provide good tensile strength in view of continuous washing of towels.
With respect to the touch of towels after sterilizing treatment, the system in accordance with the present invention does not injure the touch of the component fibers (cotton and/or vinylon, nylon, tetron). That is, when sterilized by low-humidity hot air for example, the component fibers become hard and there is a possibility of such hardened fibers harming the skins of the hands and the face to impart discomfort to the users. On the contrary, the system of the present invention may provide better finishing which imparts no discomfort to the users.
From the foregoing, it will be apparent the present invention has following advantages.
According to the present invention, since steam sterilization is performed while towels are being continuously carried in and out from the sterilizing chamber by the conveyor system 3, it is possible to avoid fiber deterioration, which is observed in a system with the use of chloric type chemicals, whereby towels treated in accordance with the present invention may be repeatedly used for a long period of time, thereby to realize economical improvements, and sterilization may be continuously performed in an effective manner.
If the sterilizing chamber S is merely filled with steam, steam comes in contact with the peripheral wall 25 of the sterilizing chamber S and is subsequently cooled to form dew. Then, there is a possibility of such dew falling on towels and getting spots thereon. However, according to the present system, the heating device 26 heats the peripheral wall 25 to restrain the formation of dew, thereby preventing towels from becoming stained, which is otherwise a result of dew falling.
Furthermore, if the sterilizing chamber S is not sufficiently filled with steam, the humidity of steam is excessively decreased from the fact that the peripheral wall 25 is heated by the heating device 26. Accordingly, the heat conduction effect is lowered too much to perform a desired sterilization.
On the other hand, if the sterilizing chamber S is excessively filled with steam in order to prevent the humidity from being decreased, it increases the running cost of the steam generator 24. However, according to the present invention, since provision is made for detecting a temperature in the sterilizing chamber S, the amount of generated steam may automatically be controlled such that the temperature and the humidity of steam in the sterilizing chamber S are maintained at 70° C. or more and 45% or more, respectively. Thus, steam generation may be restrained to such a minimum amount so as to perform a desired sterilization, thereby reducing the system running cost. As a whole, good sterilization may be performed with economical improvements.
Furthermore, according to the present invention, since sterilization is performed with steam having a predetermined humidity, it is possible to restrain to injure the touch of the component fibers of towels, thus providing a practical advantage.
When rolled towels treated according to the present invention are circulated on the market as rental goods, general bacilli are propagated in transit or during storage dependent on temperature and humidity conditions. Accordingly, it is to be noted that such rental rolled towels are to be generally rented and collected for a cycle of at most one month, in order to always use such rolled towels in a satisfactory manner and to prevent such towels from being excessively contaminated by spots and mold.
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A system for selectively collecting washed articles with a washing device and conveyor to convey the articles therethrough, first and second detectors for detecting fabric faults and improperly washed articles, respectively, a device to roll the articles, a control device for controlling the washing treatment and a distributing device in response to signals generated by the detectors.
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RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C. §119 based on U.S. Provisional Patent Application No. 61/587,760 filed Jan. 18, 2012, the disclosure of which is incorporated by reference herein in its entirety.
BACKGROUND INFORMATION
[0002] Typically, power is distributed from an insulated overhead cable either by stripping a section of the cable and using a conventional connector, or alternatively, by using an insulation piercing connector (IPC). An IPC makes an electrical contact with the cable when a conducting portion of the IPC pierces the insulation of the cable. Power is drawn from the cable via a tap that is attached to the IPC.
[0003] A typical IPC provides for a single tap. This can be a disadvantage in a crowded urban environment where multiple taps are needed to supply power to multiple dwelling units.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments described herein and, together with the description, explain the embodiments. In the drawings:
[0005] FIG. 1A is an isometric perspective top view of an exemplary insulation piercing connector (IPC) housing in a closed configuration;
[0006] FIG. 1B is an isometric perspective top view of the IPC housing of FIG. 1A in an open configuration;
[0007] FIG. 1C is an isometric perspective bottom view of the IPC housing of FIG. 1A in the open configuration, with an IPC in a position to be placed inside the IPC housing;
[0008] FIGS. 2A and 2B are top and bottom views, respectively, of the IPC housing of FIG. 1A in the closed configuration;
[0009] FIGS. 3A and 3B are top and bottom views, respectively, of the IPC housing of FIG. 1A in the open configuration;
[0010] FIGS. 4A , 4 B, and 4 C are side, rear, and front views, respectively, of the IPC housing of FIG. 1A in the closed configuration; and
[0011] FIGS. 5A , 5 B, and 5 C are side, rear, and front views, respectively, of the IPC housing of FIG. 1A in the open configuration.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0012] The following detailed description refers to the accompanying drawings. The same reference numbers in different drawings may identify the same or similar elements.
[0013] As described herein, an insulation piercing connector (IPC) housing insulates an IPC that may be used with a single duplex or triplex cable. The IPC housing prevents shorts and protects installers. In addition, the IPC housing includes a feature that may be used with a serialized utility lock to secure the housing. The feature and the lock may prevent unauthorized opening of the IPC housing, tapping the IPC within the IPC housing, and stealing power from the IPC.
[0014] FIGS. 1A , 2 A, 2 B, 4 A, 4 B, and 4 C are an isometric perspective top view, a bottom view, a top view, a side view, a rear view, and a front view, respectively, of an exemplary IPC housing 100 in a closed configuration. IPC housing 100 may contain an IPC (shown at 160 in FIG. 1C ) that is coupled to a cable (not shown). In some implementations, for example, the cable may include an overhead power line that is suspended via towers or utility poles. When the IPC is attached to the power line, the IPC and IPC housing 100 may be located/positioned at some distance (e.g., 2-8 feet) away from the body of the tower/pole. As shown in FIGS. 1 A and 4 A- 4 C, IPC housing 100 may include upper cover 102 and lower cover 104 . Upper cover 102 and lower cover 104 may be coupled together via hinge 120 . IPC housing 100 may be made of different types of material, such as a plastic molding (e.g., thermo plastic (e.g., polyethylene), rubber, etc. that may protect an installer of the IPC/IPC housing 100 and prevent wires/cables attached to the IPC from shorting.
[0015] FIGS. 1B , 3 A, 3 B, 5 A, 5 B, and 5 C are an isometric perspective top view, a top view, a bottom view, a side view, a rear view, and a front view, respectively, of IPC housing 100 in an open configuration. As shown, IPC housing 100 is initially empty prior to insertion of an IPC. Top cover 102 and bottom cover 104 provide space for containing the IPC.
[0016] FIG. 1C is an isometric perspective bottom view of IPC housing 100 in the open configuration, with an IPC 160 in a position to be placed inside IPC housing 100 . IPC 160 is typically made of a conducting material or metal, such copper alloy, steel, aluminum, etc. As shown, IPC 160 may include a body/trunk 162 , lower jaw 164 , and upper jaw 166 . In some implementations, body/trunk 162 , lower jaw 164 , and upper jaw 166 may be integrally formed in a U-shape from a single material.
[0017] Body/trunk 162 of IPC 160 may include one or more holes 176 , into which cables/lines for tapping power may be inserted. Although not visible in FIG. 1C , a top/side of body/trunk 162 may provide for threaded openings into which screws may be inserted and tightened against cables/lines in holes 176 . The screws may securely hold the ends of cables/lines in holes 176 .
[0018] Upper jaw 166 may include teeth or serration 168 on its surface facing lower jaw 164 . Depending on the implementation, teeth/serration 168 may be formed of material different from that of body/trunk 162 , upper jaw 166 or lower jaw 164 , such that teeth/serration 168 provides for higher conductivity than other portions of IPC 160 . Lower jaw 164 may include a hole whose axis is in the direction toward upper jaw 166 . The hole may accommodate a screw/bolt 170 .
[0019] When screw/bolt 170 is inserted into the hole and turned (e.g., clockwise), holding end 174 of screw/bolt 170 moves toward teeth/serration 168 of upper jaw 166 . If a cable is placed in the spacing between teeth/serration 168 and holding end 174 of screw/bolt 170 , and screw/bolt 170 is tightened (e.g., via bolt head 172 ), holding end 174 may be made to push the cable against teeth/serration 168 with sufficient force for teeth/serration 168 to pierce/penetrate the insulation of the cable, to therefore make an electrical/conductive contact with the conductor within the cable. Once cables are affixed in holes 176 and the spacing between teeth/serration 168 and holding end 174 , IPC 160 may be inserted into lower cover 104 in the direction of arrow 180 . Upper cover 102 may be closed about hinge 120 in the direction of arrow 180 . When IPC 160 is inside IPC housing 100 that is closed (e.g., FIG. 1A ), the cables attached to IPC 160 may extend from IPC 160 to the outside of IPC housing 100 through different portions of IPC housing 100 , as described below.
[0020] Referring to FIGS. 1A-1C and 3 A- 3 C, upper cover 102 may include front wall 130 - 1 , side wall 130 - 2 , rear wall 130 - 3 , side wall 130 - 4 (collectively “walls 130 ”), and a panel 110 that partially enclose/surround a cavity within upper cover 102 . As shown, walls 130 - 1 through 130 - 4 may be substantially perpendicular to panel 110 . Furthermore, each of walls 130 - 1 through 130 - 4 may be perpendicularly adjoined to two of the other walls 130 . Walls 130 - 2 and 130 - 4 include notched portions whose height (measured from panel 110 to its edge) is lower than that of walls 130 - 1 and 130 - 3 as shown in FIGS. 1B , 4 A, and 5 A.
[0021] Lower cover 104 may include front wall 132 - 1 , side wall 132 - 2 , rear wall 132 - 3 , side wall 132 - 4 (collectively walls 132 ), and a panel 134 that partially enclose/surround a cavity within lower cover 104 . As shown in FIG. 1B , walls 132 - 1 through 132 - 4 may be perpendicular to panel 134 . Furthermore, each of walls 132 - 1 through 132 - 4 may be perpendicularly adjoined to two of the other walls 132 . Walls 132 - 2 and 132 - 4 include notched portions whose height (measured from panel 134 to its edge) is lower than that of walls 132 - 1 and 132 - 3 , as shown in FIGS. 1B , 4 A, and 5 A.
[0022] In one embodiment, when IPC housing 100 is closed, the top edge surfaces of walls 130 - 1 and 130 - 3 are brought to contact the top edge surfaces of walls 132 - 1 and 132 - 3 , respectively, while the short portions of walls 130 - 2 and 130 - 4 and 132 - 2 and 132 - 4 provide for two side openings to IPC housing 100 . If IPC 160 with cables that are attached to holes 160 of IPC 160 is within IPC housing 100 , the cables would extend or project from IPC housing 100 via the side openings/gaps formed by the notched portions of walls 130 - 2 and 132 - 2 and 130 - 4 and 132 - 4 when IPC housing 100 is closed.
[0023] In one implementation, wall 130 - 2 includes fins 106 - 1 . Each of fins 106 - 1 is partially separated from other fins 106 - 1 by slits 107 , one of which is labeled in FIG. 1A . Fins 106 - 1 are attached to wall 130 - 2 such that fins 106 - 1 , from the portion attached to wall 130 - 2 , are slanted toward the plane at which walls 130 of upper cover 102 and walls 132 of lower cover 104 meet when IPC housing 100 is closed.
[0024] Similar to wall 130 - 2 , each of walls 130 - 4 , 132 - 2 , and 132 - 4 includes fins 106 - 2 , 106 - 4 , and 106 - 3 , respectively. Each of fins 106 - 2 , 106 - 4 , and 106 - 3 is attached to its respective wall in the manner described above with respect to fins 106 - 1 .
[0025] When IPC housing 100 is closed, fins 106 - 1 of wall 130 - 2 and fins 106 - 4 of wall 132 - 2 cover the opening formed by the notched portions of walls 130 - 2 and 130 - 4 . If IPC 160 with cables in holes 176 are placed within IPC housing 100 , fins 106 - 1 and 106 - 4 bend to allow the cables to extend from IPC 160 to the outside of housing 100 . Because fins 106 - 1 and 106 - 4 cover the opening formed by walls 130 - 2 and 130 - 4 , to steal power by tapping IPC 160 using wires, the wires must pass through fins 106 - 1 and 106 - 4 to reach and contact IPC 160 . Hence, fins 106 - 1 and 106 - 2 provide for protection against power theft.
[0026] Similarly, when IPC housing 100 is closed, fins 106 - 2 of wall 130 - 4 and 106 - 3 of wall 132 - 4 cover the opening formed by walls 130 - 4 and 132 - 4 . If IPC 160 with cables in holes 176 are placed within IPC housing 100 , fins 106 - 2 and 106 - 3 allow the cables to extend from IPC 160 to the outside of IPC housing 100 . Because fins 106 - 2 and 106 - 3 cover the opening formed by walls 10 - 4 and 132 - 4 , to steal power by tapping IPC 160 using wires, the wires must pass through fins 106 - 2 and 106 - 3 to reach and contact IPC 160 .
[0027] Because each of fins 106 - 1 through 106 - 4 is partially separated from other fins via slits 107 , if a cable juts out from IPC 160 through a pair of upper and lower fins, fins that are next to the pair of fins remain shut, still covering portions of the openings (in IPC housing 100 ) through which other holes 176 of IPC 160 may be accessed.
[0028] Fins 106 - 1 through 106 - 4 may be constructed to be thinner than walls 130 and 132 , so that fins 106 - 1 through 106 - 4 are more flexible than walls 130 and 132 . In some constructions, fins 106 - 1 through 106 - 4 may be tapered to be thinner as they extend from walls 130 and 132 . In some implementations, fins 106 - 1 through 106 - 4 may be made of the same material as walls 130 and 132 or other portions of IPC housing 100 . In other implementations, IPC housing 100 may be made of a different material.
[0029] As shown in FIGS. 1B and 1C , wall 130 - 3 of upper cover 102 and wall 132 - 1 of lower cover 104 are attached/connected to one another via hinge 120 . Although hinge 120 is shown as a plastic, folding type hinge, in other implementations, hinge 120 may include another type of hinge, such as a butt hinge, butterfly hinge, piano hinge, etc. Upper cover 102 and lower cover 104 may swivel relative one another about hinge 120 , to open and close IPC housing 100 . In a different implementation, IPC housing 100 may exclude hinge 120 , and upper cover 102 may be attached lower cover 104 by another component (e.g., a plastic string, wire, etc.). In some implementations, IPC housing 100 may be closed by snap-fitting upper cover 102 and lower cover 104 to one another and securing upper cover 102 and lower cover 104 with screws.
[0030] Front wall 130 - 1 of upper cover 102 may include an upper locking piece 116 , which juts away from the exterior side of wall 130 - 1 . Upper locking piece 116 is supported from front wall 130 - 1 by support members 114 - 1 , 114 - 2 , and 114 - 3 . Support members 114 - 1 , 114 - 2 , and 114 - 3 may be equally spaced apart from one another and attached to the exterior surface of front wall 130 - 1 . Furthermore, support members 114 - 1 through 114 - 3 may extend from the points of attachment, away from the surface of wall 130 - 1 in the direction perpendicular to panel 110 , toward upper locking piece 116 .
[0031] Similarly, front wall 132 - 1 of lower cover 104 may include a lower-locking piece 144 and protrusions 142 - 1 and 142 - 2 . Lower locking piece 144 and protrusions 142 - 1 and 142 - 2 extend away from the exterior surface of front wall 132 - 1 . Lower locking piece 144 is positioned under and between protrusions 142 - 1 and 142 - 2 , between the plane of panel 132 and the flats of the edges of walls 132 .
[0032] When IPC housing 100 is closed, upper locking piece 116 is placed over front wall 132 - 1 , and comes into contact with lower locking piece 144 . Protrusion 142 - 1 of front wall 132 - 1 fits into the spacing between support members 114 - 2 and 114 - 3 , and protrusion 142 - 2 of front wall 132 - 1 fits into the spacing between support members 114 - 1 and 114 - 3 .
[0033] Protrusion 142 - 1 may be shaped like a flat piece of a right triangle, with one edge of the triangle attached to front wall 132 - 1 ( FIG. 5A ). Therefore, as upper locking piece 116 is brought toward lower locking piece 144 over protrusion 142 - 1 (and protrusion 142 - 2 ), upper locking piece 116 first contacts the outer edge (i.e., the hypotenuse) of triangular protrusion 142 - 1 . The contact may prevent the upper locking piece 116 from touching lower locking piece 144 , until additional force is applied to bring upper cover 102 together with lower cover 104 . Upon application of necessary force, upper locking piece 116 may be forcibly slid over protrusions 142 and may snap into a position underneath the base of triangular protrusions 142 - 1 .
[0034] When IPC housing 100 is closed, hole 117 in upper locking piece 116 aligns with hole 146 in lower locking piece 144 , and provides for the bolt of a lock to pass there-through. When the lock is secured, the lock may prevent upper locking piece 116 and lower locking piece 144 of IPC housing 100 from separating and opening IPC housing 100 .
[0035] As shown in FIGS. 1B and 3A , upper cover 102 includes two columns 115 . The inner surface of front wall 130 - 1 adjacent to two columns 115 , which project from panel 110 to a point above front wall 130 - 1 . When IPC housing 100 is closed, the tips of columns 115 of upper cover 102 fit into corresponding groove/notches 143 on front wall 132 - 1 of lower cover 104 . Columns 115 provide for additional stability in preventing upper cover 102 from sliding laterally against lower cover 104 when IPC housing 100 is closed. In some implementations, upper cover 102 may include barbs in place of columns 115 . In such implementations, when IPC housing 100 is closed, the barbs may hook into the notches of lower cover 104 , to securely hold upper cover 102 and lower cover 104 together.
[0036] Panels 110 and 132 include holes 112 and 136 , respectively. Holes 112 and 136 allow moisture or water that sometimes collects inside of IPC housing 100 to leak/dry out and prevent the moisture from causing problems (e.g., rusting, corrosion, etc.). In addition, panels 110 and 132 may include ridges 108 and 150 in the lengthwise directions on exterior surfaces thereof. Ridges 108 and 150 provide for additional strength and rigidity to upper cover 102 and lower cover 104 .
[0037] Panel 110 includes area 111 that is clear of ridges 108 . Depending on the implementation, area 111 may display letters, logos, symbols, pictures, etc.
[0038] Walls 132 - 2 and 132 - 4 include semi-oval holes 136 - 1 and 136 - 2 , respectively. Semi-oval hole 136 - 1 extends from about the center of wall 132 - 2 to the top edge of wall 132 - 2 . Semi-oval hole 136 - 2 extends over a corresponding area in wall 132 - 4 . Holes 136 - 1 and 136 - 2 permit a cable that is held by teeth/serration 168 of upper jaw 166 and holding end 174 of screw/bolt 170 of IPC 160 to pass through IPC housing 100 while preventing or limiting unauthorized access to IPC 160 .
[0039] Walls 132 - 2 and 132 - 4 include rounded portions 140 - 1 and 140 - 2 that cover semi-oval holes 136 - 1 and 136 - 2 , respectively. As shown in FIG. 1C , rounded portion 140 - 1 protrude/bulge outwardly from the plane of wall 132 - 2 . Rounded portion 140 - 1 includes multiple crossing slits 156 that form flaps 154 in rounded portion 140 - 1 . That is, each flap 154 in rounded portion 140 - 1 is cut or separated from other flaps through slits 156 . As shown in FIGS. 1C , 4 A and 5 A, a central slit 158 extends from the center of rounded portion 154 toward fins 106 - 4 . Rounded portion 140 - 2 is constructed similarly as rounded portion 140 - 1 .
[0040] When a cable is held by upper teeth/serration 168 of upper jaw 166 and holding end 174 of screw 170 , and IPC 160 is inserted into lower cover 104 (in the direction of arrow 180 ), the cable may be substantially perpendicular to the planes of walls 132 . As IPC 160 is inserted into lower cover 104 , the cable pushes against the middle of fins 106 - 4 and 106 - 3 . As IPC 160 is pushed further into lower cover 104 , fins 106 - 4 (and fins 106 - 3 ) are separated, giving way to central slit 158 of rounded portion 140 - 1 . As IPC 160 is pushed further into lower cover 104 , individual flaps 154 of rounded portion 140 - 1 (and 140 - 2 ) are also separated, to accommodate the cable. At this point, each of the individual flaps 154 outwardly extend from the plane of wall 132 - 2 along the surface of the cable, gripping the cable. Rounded portion 140 - 2 and corresponding flaps 154 may be constructed similarly as rounded portion 140 - 1 and its flaps 154 and may operate similarly.
[0041] When IPC 160 is inside IPC housing 100 and IPC housing 100 is closed, because flaps 154 protrude outward and away from walls 132 - 2 and 132 - 4 and they apply force to the cable held by teeth/serration 168 and holding end 174 associated with IPC 160 , accessing IPC 160 through flaps 154 and tapping IPC 160 to steal power may be difficult. In some implementations, to provide flexibility to flaps 154 , each of flaps 154 may be constructed such that each flap's thickness is tapered from its base near wall 132 - 2 (or 132 - 4 ) toward its tip. In addition, depending on the implementation, flaps 154 may be made of a material different form that of walls 132 .
[0042] As described above, IPC housing 100 insulates and/or protects IPC 160 that may be used with a duplex or triplex cable. IPC housing 100 prevents shorts and protects installers. In addition, IPC housing 100 includes upper locking piece 116 and lower locking piece 144 that may be used with a serialized utility lock (or another type of lock) to secure IPC housing 100 . Upper locking piece 116 , lower locking piece 144 and the lock may prevent unauthorized opening of IPC housing 100 , tapping IPC 160 within IPC housing 100 , and stealing power from IPC 160 .
[0043] The foregoing description of implementations provides illustration, but is not intended to be exhaustive or to limit the implementations to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from practice of the teachings.
[0044] For example, walls 130 - 2 and 132 - 2 and walls 130 - 4 and 132 - 4 are described above as forming openings for wires that tap IPC 160 within IPC housing 100 . In other implementations, walls 132 - 2 and 132 - 4 may include holes, similar to holes 136 - 1 and 136 - 2 , for accommodating wires that tap IPC 160 . In such implementations, in place of fins 106 - 1 through 106 - 4 , walls 132 - 2 and 132 - 4 may include a number of portions that are similarly constructed as rounded portions 140 - 1 and 140 - 2 (e.g., having a central slit and flaps), to protect IPC 160 against unauthorized access.
[0045] Although different implementations have been described above, it is expressly understood that it will be apparent to persons skilled in the relevant art that the implementations may be modified without departing from the spirit of the invention. Various changes of form, design, or arrangement may be made to the invention without departing from the spirit and scope of the invention. Therefore, the above mentioned description is to be considered exemplary, rather than limiting, and the true scope of the invention is that defined in the following claims.
[0046] No element, act, or instruction used in the present application should be construed as critical or essential to the implementations described herein unless explicitly described as such. Also, as used herein, the article “a” is intended to include one or more items. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise.
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A housing for retaining an insulation piercing connector (IPC) includes an upper housing, a lower housing, and a hinge. The lower housing includes a cavity formed therein. The hinge is coupled to the upper housing and the lower housing to permit movement of the upper housing and the lower housing into open and closed configurations. When in the closed configuration, the upper housing is aligned with the lower housing. The second cavity is configured to received\ the IPC. The lower housing includes an aperture formed transversely therethrough for receiving a cable extending from the IPC upon receipt of the IPC into the second cavity.
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FEDERALLY SPONSORED RESEARCH
Not Applicable
SEQUENCE LISTING OR PROGRAM
Not Applicable
BACKGROUND
1. Field of Invention
The paint brush case relates to the field of paintbrush containers, specifically to the way in which commercial paint brushes, which have been cleaned of paint and the like, are stored.
2. Description of Prior Art
Most, if not all modern professional-model paintbrushes, are designed to have long, productive life spans, and are purchased at considerable expense. It is logical that painters, and other users of paintbrushes, would want to take full advantage of these design qualities, and get a full return on their investment. Paintbrush manufacturers typically include a paper folder, or a plastic sleeve with the purchase of a brush, as means to maintain its form during shipping and selling. These folders and sleeves are very often not durable enough to withstand the rigors of commercial use, and quickly fall apart. Brushes with no protective cases are easily damaged by pressures that force bristles out of alignment. Crimping or splaying of bristles make fine brushwork extremely difficult, drips more likely, and are virtually impossible to repair. Brushes that are stored in liquid, or are not given opportunity to dry, are subject to rusting of their metal parts and dissolution of their binding glue. Therefore, the question of what to do with a paintbrush between uses, so that it remains in good operational condition, is a very valid one, and has been often addressed by inventors as evidenced in the prior art.
Inventors in the field of paintbrush protection and storage, have proposed numerous devices for covering the ferule and bristles in a more durable individual protective wrapper or case; other examples in the prior art teach various cases and brush boxes for keeping bristles of a plurality of brushes submerged in a solvent; and still others demonstrate devices for storing clean artist's brushes. To the knowledge of the inventor, there is not a case specifically designed to store and protect a plurality of dry, clean (free of paint and the like) commercial paint brushes in either in the prior art or commercially available.
Known prior art further includes: Albanese, U.S. Pat. No. 1,979,241; Adams, U.S. Pat. No. 2,150,706; Kurath, U.S. Pat. No. 2,479,509; Drinkwater, U.S. Pat. No. 2,278,650; Pichniarczyk U.S. Pat. No. 2,479,509; Crozier U.S. Pat. No. 4,756,405; Sica, U.S. Pat. No. 5,097,967.
OBJECTS AND ADVANTAGES
Accordingly, the present invention has a range of functionality as yet unseen in combination for the express purpose of storing and preserving paintbrushes. Objects and advantages of my invention are:
(a) to provide a method of storing commercial paint brushes indefinitely so they will retain their forms, and not be damaged in anyway by external forces;
(b) to provide a method of transporting several paint brushes more easily between locations;
(c) to provide a method of organizing paint brushes so they can be easily identified;
(d) to provide a method of storing paint brushes so they can be easily and individually accessed;
(e) to provide a storage environment where clean, wet paintbrushes may be allowed to dry without threat to their form;
(f) to provide a single container for storing commercial paintbrushes of varying dimensions and styles;
(g) to provide a method of storing paint brushes that helps prevent the loss of individual paintbrushes through misplacement;
(h) to provide a means of storing, and protecting paint brushes in a case that is very easy to use;
(i) to provide a means of storing paintbrushes that makes economical use of space;
(j) to provide a means of storing paintbrushes where the mechanism that anchors the brush is straightforward and reliable;
(k) to provide a method of protecting commercial paintbrushes during transport so they will retain their forms and not be damaged in any way.
SUMMARY
The above mentioned objects and related objects in accordance with the present invention, are accomplished through a lower tray, connected by hinges to a lid in such a way that when closed a self-contained box is defined. The lower tray is characterized by a series of horizontal pins mounted perpendicularly to supports, and are vertically and horizontally aligned with individual recesses in a bridge that laterally bisects the lower tray adjacent to the pins. The lower tray is divided longitudinally ahead of the lateral divider, into protective compartments to contain bristles and the ferule of paintbrushes. The lid is likewise bisected by a nearly congruent lateral press, in which syncline embrasures are aligned in such a way that when the lid is in the closed position, the embrasures form alternating apertures and seals with the recesses of the lateral bridge of the tray. Bumpers near the pins and on the longitudinal dividers vertically align the brushes and keep them in place. Further advantages of this invention, both to its construction and mode of operation 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.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings represent a particular embodiment of the invention in a preferred form.
FIG. 1 is a perspective view of a paintbrush case in the open position.
FIG. 2 a is a sectional enlargement in plan view along the line 1 — 1 of FIG. 1 .
FIG. 2 b is a sectional detail in orthographic view taken along line 2 — 2 of FIG. 2 a.
FIG. 2 c is similar to FIG. 2 b but in perspective view.
FIG. 3 is a perspective view of the paintbrush case from FIG. 1 in the fully closed position with a partial sectional showing the internal coupling of the two halves.
FIG. 4 is a similar view to FIG. 2 c except with a paintbrush fragment illustrating step one and two in the operation of the invention.
FIG. 5 is a sectional enlargement in plan view showing the internal cooperation of the two halves in securing paintbrushes.
FIG. 6 is a sectional enlargement in plan view along line 3 — 3 of FIG. 1, showing the case from FIG. 1 in the fully closed position, and a paintbrush held securely in place.
FIG. 7 is a plan view from above of the paintbrush case from FIG. 1 disposed in the fully open position, showing stored paintbrushes.
LIST OF REFERENCE NUMERALS:
10 paint brush case
12 lid
14 l lid wall left
14 b lid wall back
14 r lid wall right
14 f lid wall front
16 ceiling
20 press
22 embrasure
24 upper seal
26 tray
28 l case wall left
28 b case wall back
28 r case wall right
28 f case wall front
30 floor
32 case handle
34 l buckle left
34 r buckle right
38 l hinge left
38 r hinge right
40 window
42 a tray seal
42 b lid seal
44 bumper platform
46 access ramp
48 anchor support
50 anchor pin
54 pin bumper
58 anchor array
60 bridge
62 recess
64 lower seal
66 ferule trap
68 ferule bumper
70 divider
72 bristle compartment
73 fence
74 aperture
76 display hole
80 paintbrush
82 bristles
84 ferule
86 paintbrush handle
DETAILED DESCRIPTION
In the drawings, closely related figures have the same number but different alphabetical suffixes. Also like numerals designate like parts throughout the figures. Also, multiple incidences of identical parts in single figures are only identified once.
Describing more particularly the specific construction of the embodiment of the invention illustrated in FIG. 1, a paint brush case 10 is in the present instance, but not necessarily rectangular, being formed by a hinged lid 12 and a tray 26 , both being of very similar dimension. It may be equipped as shown with buckles 34 r , 34 l , and a case handle 32 . The case 10 is preferably made of resilient, thermoplastic material such as polypropylene or the like, and is preferably constructed by, though is not limited to, plastic injection molding.
FIG. 1 shows a perspective view of the open paintbrush case 10 , showing a left hinge 38 l and right hinge 38 r connecting the lid 12 with the tray 26 . The interior cavity of the lid 12 is defined by 2 congruent parallel lid side walls right and left, 14 r 14 l respectively, joined at right angles to a lid back wall 14 b which is congruent with a parallel lid front wall 14 f . A ceiling 16 joins with right angles at its edges with the lid walls 14 r , 14 l , 14 b , 14 f . An upper case seal 42 b is a concentric lip formed by the linear edges of the contiguous walls.
FIG. 1 further shows that the interior cavity of the tray 26 is similarly defined by 2 congruent parallel side case walls, left and right, 28 l and 28 r respectively, joined at right angles to a case back wall 28 b which is congruent with a parallel front case wall 28 f . A floor 30 joins at right angles to the case walls 28 l , 28 r , 28 f , 28 b . A concentric lower case seal 42 a is formed by the linear edges of the contiguous walls. Case wall back 14 b and case wall front 14 f are also characterized by a plurality of windows 40 . Each window 40 is circular in shape and is cut out of the case walls front and back, 14 f and 14 b respectively, to facilitate air flow over the paintbrush bristles. The tray 26 and lid 12 are constructed, aligned and hinged complimentary to each other so that in the closed condition thereof, they cooperate to form a closed container, as shown in FIG. 3 .
FIG. 1 further reveals that connected at right angles between lid wall front 14 f and lid wall back 14 b , and likewise connected perpendicularly to the ceiling 16 , is a press 20 . The press 20 laterally traverses the lid 20 , effectively dividing the interior cavity of the lid 12 into two compartments. The side of the press 20 which runs parallel to the ceiling 16 , and which has no point of attachment in the open position, is characterized by a series of embrasures 22 , alternating with a series of planar upper seals 24 . Each embrasure 22 is defined by two obtuse planes that terminate at their intersection so that a series of inverse “V” shapes are cut out of the press 20 . Each instance of the embrasure 22 occurs between instances of the upper seal 24 . Each upper seal 24 is comprised of a planar surface, oriented parallel with the planer surface of the ceiling 16 and is separated by like instances of the embrasure 22 . Just as lid wall front 14 f and lid wall rear 14 r delimit the press 20 , so do they designate the endpoints of the polar incidences of the upper seal 24 .
Referring now to FIG. 2 a , traversing the case 26 from case wall rear 28 r to case wall front 28 f , and connected perpendicularly to same, as well as connected perpendicularly to case floor 30 is an anchor array 58 . The anchor array 58 is comprised of a bumper platform 44 , a series of slot bumpers 54 , a series of anchor supports 48 , and a series of pin anchors for supporting a plurality of paintbrushes. The bumper platform 44 extends the full width of the tray 26 , near to but not touching case wall right 28 r . The bumper platform 44 is attached to the case wall back 28 b and case wall front 28 f and to the floor 30 . FIG. 2 b shows the bumper platform 44 is trapezoidal in shape, where the upper surface lies parallel to the floor 30 . The only side not at right angles with the others is an access ramp 46 , which rises from the floor 30 at an acute angle.
Protruding from the bumper platform 44 and the access ramp 46 is the anchor support 48 . The anchor support 48 rises perpendicularly from the bumper platform 44 , and is characterized by two symmetrical parallel planes, and from each plane emanates the anchor pin 50 . The anchor pin 50 protrudes at a right angle from the plane of the anchor support 48 , and is positioned over the access ramp 44 , at such a distance there from as to accommodate the handle end of a typical commercial paintbrush. The anchor pin 50 is cylindrical in shape and its length and circumference are such that it may secure a standard commercial paintbrush, as illustrated in FIG. 4 . Each plane of the anchor support 48 is designed to accommodate a single brush.
Referring specifically to FIG. 2 c , anchor support 48 elements generally have two planes except for that instance designated to accommodate the final brush in a case 10 configured to store an odd number of brushes. Here the case wall back 28 b forms the second plane, and the anchor support 48 would be able to accommodate only one brush. Instances of the anchor support 48 are positioned on the bumper platform 44 at distances from each other so that when bearing an anchor pin 50 of a length sufficient to secure a standard commercial paintbrush, there is enough space for a standard commercial paintbrush to pass between the two facing anchor pins 50 , as can be seen in FIG. 2 a.
Additionally, the bumper platform 44 supports a pin bumper 54 . The pin bumper 54 in the present embodiment is cylindrical in shape and extends upwards from the upper plane of the bumper platform 44 . The pin bumper 54 must be short enough to allow brush handles to easily access the anchor pin 50 when being placed in the case 10 or taken out thereof, but must be tall enough to keep any brush at rest in the case 10 from laterally slipping off the anchor pin 50 . In the preferred embodiment each instance of the pin bumper 54 is alike, and they are positioned on the bumper platform 44 between each incident of the anchor support 48 .
Referring again to FIG. 1, spanning the full width of the tray 26 is a bridge 60 . The bridge 60 is attached to case wall back 28 b , case wall front 28 f , and the case floor 30 , with a similar alignment in the tray 26 , as the press 20 has in the lid 12 . The bridge 60 is characterized by a flat, elevated lower seal 64 , and a series of square-shaped recesses 64 . The recesses are cut out to a depth and width that they can accommodate a wide range of paintbrush handle styles, and secure them with reasonable tightness. The lower seals 64 separate each instance of the recess 62 .
Referring to FIG. 3 now, the planar dimensions of the lower seal 64 are substantially the same as those of the upper seal 24 and have the same alignment, so that when the case 10 is in the closed position, each instance of the upper seal 24 will come to rest in an adjacent position to the corresponding instance of the lower seal 64 . Additionally, each instance of the embrasure 22 comes to rest in line with a corresponding instance of the recess 62 , thereby creating a series of uniform apertures 74 . In the preferred embodiment the bridge 60 and the press 20 are of such dimension that when the case 10 is in the closed position, lower seal 64 forms a reasonable seal with upper seal 24 .
As seen most clearly in FIG. 7, each instance of the recess 62 will necessarily be in alignment with a corresponding instance of the handle pin 50 in order for the case 10 to be functional. In the same way, each instance the lower seal 64 is aligned with alternating instances of either the pin bumper 54 , or the anchor support 48 , there by creating conduits to accommodate stored paintbrushes.
Referring again to FIG. 1, emanating from each instance of the lower seal 64 is a divider 70 . The divider 70 is comprised of a ferrule trap 66 , a ferule grip 68 , and a fence 73 . The divider 70 is attached to the bridge 60 and the case floor 30 at right angles, and extends towards case wall left 28 l on a line parallel to case wall front 28 f and case wall back 28 b . Each divider 70 is attached to the bridge 60 only at the lower seal 64 , and is less wide than the lateral planar dimension of the lower seal 64 . Each instance of the divider 70 is parallel to each other like instance, and between each two instances is an empty bristle compartment 72 . The ferule trap 66 is that part of the divider 70 which attaches to the bridge 60 , and is characterized by a lateral dimension greater than the divider 70 , but less than that of the lower seal 64 . The dimensions of the ferule trap 66 are such that the ferule of a standard commercial paintbrush may pass closely between two adjacent instances. The ferule trap 66 supports the ferrule grip 68 , which is attached in a vertical orientation. The ferule grip 68 is made of highly durable rubber or some other substance with similar flexible properties. Each instance of the ferule trap 66 supports a plurality of substantially identical instances of the ferule grip 68 , which protrudes from the ferule trap 66 in such a way that it may contact the ferule of a stored paintbrush, but not arrest its descent. In the present embodiment the height of the dividers is the same as the ferule trap 66 . This height is sufficient that each brush laid to rest in the case 10 , is effectively segregated from any other brush, but is not so high as to interfere with the closing of the lid 12 .
OPERATION
Referring to FIG. 4, the manner of using the paintbrush case 10 to store a standard commercial paintbrush 80 should be evident to those skilled in the field. Virtually every mass produced commercial paintbrush 80 has a display hole 76 through the end of its handle so that it may be displayed on a hook or the like while for sale. Approaching the open case 10 with at least one unoccupied anchor pin 50 , the end of the brush handle 86 is positioned over the access ramp 46 , and moved to such an angle that the anchor pin 50 may be inserted through the display hole 76 , without progress being impeded by either the brush handle 86 striking the pin bumper 54 , or the end of the brush handle 86 contacting the access ramp 46 , the floor 30 or the case wall right 28 r . Once the end of the anchor pin 50 has been inserted through the display hole 76 , the paintbrush 80 can be maneuvered the full width of the anchor pin 50 , so that is flush with the anchor support 48 , as illustrated by arrow A. Then the paintbrush 80 may be rotated by the secured end of the handle 86 as illustrated by arrow B.
Looking at FIG. 6, when the paintbrush 80 is flush with an anchor support 48 , the paintbrush 80 will be automatically aligned with one of the recesses 62 in the bridge 60 , and bristle compartments 72 , corresponding to the present anchor pin 50 . After all brushes 80 have been likewise placed in their respective recesses 62 , the operation is simply completed by closing the lid 12 . Closing the lid 12 positions the embrasures 22 over the recesses 62 in such a way that the handle 86 of the brush 80 is held securely, and that any vertical movement of the handle 86 is kept to a minimum, as demonstrated in FIG. 5 .
In FIG. 7, likewise the width of the recess 62 ensures a minimum of horizontal movement, but for those brushes that have thinner handles and wider ferules, the ferule grip 68 works to stabilize the brush in a vertical position, to prevent the bristles 82 from contacting any part of the case 10 . The anchor pin 50 ensures that there is no longitudinal motion, and the pin bumper 54 prevents the brush 80 from slipping off the handle anchor 50 while it is in the lowered position. The dividers 70 keep each brush separate from the next, and keep the bristles 82 of the brushes 80 in good alignment. Thus, the bristles 82 of the brush 80 are suspended, the brush 80 is immobile, and the brush 80 remains secure and protected regardless of the position of the case 10 . A brush 80 is removed from the case 10 simply by opening the lid 12 , rotating the brush 80 up from the recess 62 , and sliding it off of the anchor pin 50 .
CONCLUSION, RAMIFICATIONS AND SCOPE
Thus, it can be seen the that the paint brush case provides a simple, reliable solution to a host of problems in the field of paintbrush storage. The paint brush case is designed to accommodate equally a wide variety of brand names and styles. The paint brush case also makes it easy to transport a plurality of paint brushes while preserving their shape. The paint brush case also allows for easy identification of brushes and fast individual access to each brush. While there has been described what is at present the preferred embodiment of the invention, it will be understood that various modifications may be made therein, and it is intended to cover in the appended claims all such modifications as fall within the true spirit and scope of the invention.
Modifications may include, but are not limited to paintbrush cases of similar purpose for more or fewer paintbrushes as disclosed here. Furthermore, tray dividers may be of variable height, or not present therein whatsoever. Windows providing ventilation may be differently configured or positioned than described here. Accordingly, the scope of the present invention should be determined not by the embodiments, but by the appended claims and their legal equivalents.
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A case for storing a plurality of commercial paint brushes comprised of a hinged lid and tray. Paintbrushes are suspended in the air through the cooperation of the handle pin, which secures a single brush's lower handle by its display hole, and a forward serrated bridge of aligned recesses which support the brush at the upper handle. The brush is locked in place by the closing of the lid when syncline divots in a lid mounted press form alternating seals and apertures with the recesses of the lower bridge. Brushes are kept vertically oriented through rubber protrusions forward of the apertures. The brush is prevented from slipping off the pin anchoring the handle by a bumper which cannot be cleared by the handle when a brush is in the horizontal locked position. Dividers keep the brushes segregated and the bristles protected.
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TRADEMARKS
IBM® is a registered trademark of International Business Machines Corporation, Armonk, N.Y., U.S.A. Other names used herein may be registered trademarks, trademarks or product names of International Business Machines Corporation or other companies.
BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to an apparatus for extracting and inserting a card relative to a surface-mount (SMT) connector, and particularly to an apparatus for extracting and inserting a dual in-line memory module (DIMM) a fixed SMT DIMM socket connector.
DESCRIPTION OF BACKGROUND
In computer systems such as personal computers, a socket is referred to as an electrical connector generally mounted on a motherboard (main board) in order to connect extension boards such as extended interface boards for peripheral devices or extended memory boards to the motherboard. The motherboard and extension boards can be electrically connected by plugging the extension boards into the electrical connector.
The structure of a common electrical connector will be described here with the example of an electrical connector used to connect an extension memory module (hereinafter, “module”) referred to as a DIMM (dual in-line memory module) as illustrated in FIGS. 1 and 2 . This module corresponds to the extension board described above.
A dual in-line memory module (DIMM) is more and more popular for use in the present PC industry, and thus uses a DIMM socket connector mounted on the motherboard for mechanical and electrical interconnect of the corresponding DIMM therein for signal transmission between the motherboard and the DIMM. A main feature of the typical DIMM connector as illustrated in FIGS. 1 and 2 is that the DIMM connector 10 includes generally a pair of latch/eject members 12 disposed at opposite ends of a connector body 14 so that such DIMM may not only be properly retained in the DIMM connector 10 without possibility of inadvertent withdrawal by vibration or external impact, but also easily ejected from the DIMM connector 10 by manual rotational movement of the latch/eject member 12 facilitated by thumb grips 16 disposed on top of the latch/eject member 12 .
Conventionally, the modules are inserted into the socket connector by hand. New advances in dual in-line memory modules (DIMM), however, are not as amenable to installation by hand as previous DIMM devices. For example, dynamic random access memory (DRAM) modules, such as double date rate (DDR) modules having 184 interface contact positions, are now being replaced with newer modules (e.g., DDRII modules) having 240 interface contact positions. Due to a larger number of pin contacts in a relatively small area in the newer memory modules, larger insertion forces are generated when installing the memory modules into socket connectors on the motherboard. Furthermore, due to limited space and high force requirements to disengage the DIMM surface-mount (SMT) latches, manual insertion and extraction is difficult and inefficient, and often leads to the possibility of damage to both the DIMM cards and SMT joints. The increased insertion force to engage the memory module, as well as the extraction force to disengage the memory module, to and from the connector, respectively, as well as the high force required to disengage the SMT latches, presents several problems which need to be addressed.
For example, the applied force to overcome the mechanical resistance of the memory modules insertion into the connector on the motherboard tends to flex or bow the motherboard. Particularly with respect to the increasing use of ball grid array (BGA) technology to mount the modules to the motherboard, deflection of the motherboard as the memory modules are installed tends to fracture the BGA connections and compromise the integrity of the electrical connection between the memory modules and the motherboard.
Also, as a user installs such memory modules by hand, and as the user pushes down on the memory modules with a greater force to insert them into the socket connectors, it is difficult to keep the memory module properly aligned with the socket connectors. In particular, unless the insertion force is very carefully applied, the memory module can easily become tilted or angled with respect to the socket connector, which can further frustrate insertion of the memory module into the connector. This may lead the user to apply still more force to the module to attempt to insert the module into the connector, and potentially lead to damage to one or both of the memory module and the connector.
Additionally, the larger insertion forces may introduce discomfort and fatigue to the end users who must install and remove them, either of which can lead to improper or incomplete installation of the memory modules. In turn, this can compromise the performance of the computer system and lead to customer dissatisfaction.
Accordingly, there is a need for a device capable of inserting and extracting a DIMM Memory Card (e.g., single high, double high, quad high) to and from a computer system.
SUMMARY OF THE INVENTION
The shortcomings of the prior art are overcome and additional advantages are provided through the provision of an apparatus for an apparatus for extracting and inserting a circuit card into a socket, the apparatus includes a tool device releasably mountable to opposing sides defining the circuit card. The tool device includes a pair of frame members having a friction fit feature for attachment to the opposing side edges defining the circuit card; and a sliding plane translatable between the pair of frame members. Upward translation of the sliding plane relative to the fixed pair of frame members acts to release latches on the connector to extract the circuit card from the connector upon upward translation of the pair of frame members, and downward translation of the sliding plane relative to the fixed pair of frame members acts to transfer a force to the circuit card, thereby inserting the circuit card with the connector. The apparatus further includes a tool guide having two members opposing each other, each member including a plurality of slots, each configured to guide a respective edge of the tool device therethrough for alignment with the connector.
In another exemplary embodiment, a system includes: a motherboard; a plurality of electrical connectors surface mounted to the motherboard, each electrical connector including a connector body configured to receive and electrically connect an electrical module; a tool device releasably mountable to opposing sides defining the electrical module. The tool device includes a pair of frame members having a friction fit feature for attachment to the opposing sides defining the electrical module; and a sliding plane translatable between the pair of frame members. Upward translation of the sliding plane relative to the fixed pair of frame members acts to release latches on the electrical connector to extract the electrical module from the electrical connector upon upward translation of the pair of frame members, and downward translation of the sliding plane relative to the fixed pair of frame members acts to transfer a force to the electrical module, thereby inserting the electrical module with the electrical connector. The system further includes a tool guide having two members opposing each other, each member including a plurality of slots, each configured to guide a respective edge of the tool device therethrough for alignment with the electrical connector.
Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the invention. For a better understanding of the invention with advantages and features, refer to the description and to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 illustrates a perspective view of a conventional DIMM connector;
FIG. 2 illustrates an elevation end view of the DIMM connector of FIG. 1 and another DIMM connector surface mounted to a PCB surface of a motherboard (show module 14 );
FIG. 3 illustrates a perspective view of a DIMM insertion tool assembly and a DIMM connected thereto for insertion with the DIMM connector surface mounted to the motherboard of FIG. 2 in accordance with an exemplary embodiment of the present invention;
FIG. 4 illustrates an exploded perspective view of an extraction tool device for use with the DIMM insertion tool assembly of FIG. 3 rotated 180 degrees and including a pair of opposing frame members having an extraction plane member therebetween in accordance with an exemplary embodiment of the present invention;
FIG. 5 illustrates a top plan view of the extraction tool device of FIG. 4 showing a top frame member removed therefrom in accordance with an exemplary embodiment of the present invention;
FIG. 6 illustrates a top plan view of an exemplary embodiment of a lever arm for use in the extraction tool device of FIG. 5 in accordance with an exemplary embodiment of the present invention;
FIG. 7 illustrates a partial top plan view of the extraction tool device of FIG. 4 and lever arm of FIG. 6 installed therewith at an initial starting position in accordance with an exemplary embodiment of the present invention;
FIG. 8 illustrates a partial top plan view of the extraction tool device of FIG. 7 illustrating the lever arm at a final position when the extraction plane is translated upwards in accordance with an exemplary embodiment of the present invention;
FIG. 9 illustrates a partial perspective view of interlocking friction teeth disposed on the pair of opposing frame members of the extraction tool device of FIG. 5 as a means for containing the DIMM in accordance with an exemplary embodiment of the present invention;
FIGS. 10 and 11 illustrate partial perspective views of the opposing frame members having the interlocking friction teeth disposed thereon for frictional engagement with opposing side edges of the DIMM in accordance with an exemplary embodiment of the present invention; and
FIGS. 12-14 illustrate top plan views of various exemplary embodiments of configurations of insertion plane members in accordance with exemplary embodiments of the present invention.
The detailed description explains the preferred embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings in greater detail, the structure of a common electrical connector will be described here with the example of an electrical connector used to connect an extension memory module (hereinafter, “module”) referred to as a DIMM (dual in-line memory module). This module corresponds to the extension board described above.
Referring to FIGS. 2-4 , an exemplary embodiment of a DIMM tool assembly will be described in further detail. FIG. 3 is a perspective view of a DIMM tool assembly 100 and a DIMM 102 connected thereto for insertion with the DIMM connector body 14 surface mounted to the motherboard 18 of FIG. 2 in accordance with an exemplary embodiment of the present invention. The DIMM tool assembly 100 includes a tool guide 110 and an insertion/extraction tool device 120 . The insertion/extraction tool device 120 includes a pair of opposing frame members 130 and a sliding plane member 140 / 150 . The sliding plane member is either an insertion plane member 140 ( FIG. 10 ) or an extraction plane member 150 , depending on whether the tool device 120 is being used for insertion or extraction of the DIMM 102 , respectively.
The tool guide 110 is referred to as a “node comb” guide configured as a slotted guide feature. The tool guide 110 allows for the mobile memory insertion/extraction tool device 120 to be properly aligned with a respective connector body 14 . By properly aligning the tool device 120 with a corresponding connector, a greater degree of operator accuracy is obtained and the possibility of accidental slipping which could potentially damage multiple memory cards, joints, surrounding hardware, and the print circuit board (e.g., motherboard 18 ), is alleviated. The tool guide 110 may be fixed within the system frame (not shown), be mobile and set into or on the system for servicing and removed or even be stored in a free location within the system frame.
While the tool guide 110 is not attached to the actual tool device 120 , it serves as an important locating tool in the insertion process of the DIMM 102 with a respective connector body 14 . In an exemplary embodiment as illustrated in FIG. 3 , the tool guide 110 is configured as a comb-like guide which can be varied along with the extraction/insertion tool device 120 to meet the specifications of the application. For example the tool guide 110 may be made in two pieces, as illustrated in FIG. 3 , fixed to a frame or configured as one piece which can be moved.
As illustrated in FIG. 3 , the tool guide 110 includes two separate members 160 opposing each other. Each member 160 includes a plurality of slots 162 . Each slot 162 is configured to guide a respective edge 164 of the tool device 120 therethrough.
Referring to FIGS. 4 and 5 , the extraction plane 150 is a sliding extraction plane which is used in extraction applications of the tool assembly 100 . The extraction plane 150 is sandwiched between the two frame members 130 and located using raised circular protrusions 166 (three shown in FIG. 5 ) extending from at least one of the frame members 130 . The extraction plane 150 is configured with guide slots 168 each of which receiving a corresponding raised circular protrusion 166 therethrough, thus defining a path for the extraction plane 150 to slide along. The raised circular protrusions 166 are sites for fasteners (not shown) in which to couple the opposing frame members 130 together once the extraction plane 150 is slidably disposed therebetween.
The sliding of the extraction plane 150 relative to the three protrusions 166 causes a lever arm 170 to rotate, which will be described hereinbelow with reference to FIGS. 5-8 . The lever arm 170 is a removable component in the extraction/insertion tool device 120 in which the lever arm 170 disengages the DIMM 102 from its respective connector body 14 . The lever arm 170 is defined by a top portion 172 and a lower portion 174 . The lower portion 174 includes a gear feature 176 configured to mesh with the thumb grips 16 disposed on top of the latch/eject member 12 . In particular referring to FIG. 6 , translation of the top portion 172 of the lever arm 170 in a direction indicated by arrow 178 causes the lever arm 170 to rotate about a pivot 180 in a direction indicated by curved arrow 182 . As the lower portion having the gear feature 176 configured as a gear-like toe of the lever arm 170 rotates, the gear feature 176 engages the thumb grips 16 disposed on top of the latch/eject member 12 and disengages the respective latch 12 .
The gear-like lower portion 174 of the lever arm 170 having this gear feature 176 interfaces with the memory latch 12 , which holds the DIMM in place with respect to the connector body 14 , and in doing so opens the latch 12 and frees the DIMM for removal. The necessary latch interaction occurs from the rotation of the lever arm 170 , which is initiated by translation of the top portion 172 of the lever arm 170 in the direction of arrow 178 .
Referring to FIGS. 5-8 , the lever arm-sliding plane mechanism will be described as the functional part of the insertion/extraction tool device 120 . By applying an upward pressure on the extraction plane 150 indicated by arrow 184 in FIG. 5 , the top portion 172 of the lever arm 170 is forced inward in the direction of arrow 178 and rotated about pivot 180 in the direction of curved arrow 182 . A finger-like feature or resetting finger 186 extends from each side of the extraction plane 150 to allow for a simple resetting of the tool device 120 by wedging the lever arm 170 back into an initial start position, as illustrated in FIG. 7 .
More specifically, FIG. 7 illustrates the initial starting position as the extraction plane 150 is lifted up the lever arm 170 pivots in the direction of curved arrow 182 . The pivoting of lever arm in the direction of curved arrow 182 is a result of a wider portion 188 of the extraction plane 150 coming into contact with the top portion 172 of the lever arm 170 as the extraction plane is lifted up in the direction of arrow 184 . Each outboard side of the extraction plane 150 is defined by an outer wider portion 188 and an inward resetting finger 186 facing the outer wider portion 188 . The outer wider portion 188 and an inward resetting finger 186 define a cavity 190 which surrounds the top portion 172 of the lever arm 170 .
FIG. 8 illustrates a final position after the extraction plane 150 is lifted up in the direction of arrow 184 . When the extraction plane 150 is returned to the initial position of FIG. 7 , the resetting finger 186 moves downward causing the pivot arm 170 to rotate in a direction of curved arrow 192 .
Referring again to FIGS. 4 and 5 , the frame members 130 and extraction plane 150 each have a handle portion 194 and 196 , respectively. The respective handle portions 194 and 196 are offset from one another to allow squeezing together in order to bias the extraction plane 150 in direction of arrow 184 , as will be recognized by one skilled in the pertinent art.
Referring now to FIGS. 9-11 , interlocking friction teeth 194 are used as a means of containing the DIMM 102 within the tool device 120 . FIG. 9 illustrates a partial perspective view of interlocking friction teeth 194 disposed on the pair of opposing frame members 130 of the extraction tool device 120 of FIG. 5 as a means for containing the DIMM 102 in accordance with an exemplary embodiment of the present invention. FIGS. 10 and 11 illustrate partial perspective views of the opposing frame members 130 having the interlocking friction teeth 194 disposed thereon for frictional engagement with opposing side edges of the DIMM 102 in accordance with an exemplary embodiment of the present invention. Each frame member 130 has a plurality of the friction teeth 194 arranged along a portion of each opposing inward edge defining an opening in which to receive the DIMM 102 . On extraction, the tool device 120 is located to the card and slid around the DIMM 102 and held onto by the interlocking friction teeth 194 . As soon as the DIMM 102 is released from the system it is already held, supported and protected by this feature of the tool device 120 . This method is particularly useful because it allows for the DIMM 102 to be manually handled as little as possible, and thus, the memory card 102 is protected from being dropped, component damage, etc. The friction teeth 194 are disposed alternately on both sides of the respective frame member 130 , and in doing so, when opposing frame members 130 are assembled, each side supporting the memory card 102 has a complete set of interlocking teeth 194 , which hold the card in place.
Referring now to FIGS. 12-14 , interchangeable sliding insertion planes 140 , 240 , 340 , respectively, are used for the insertion application of the insertion/extraction tool device 120 . The insertion planes 140 , 240 , 340 vary in size to account for the different sizes of memory cards 102 being used. By removing the lever arm 170 and replacing the extraction plane 150 with the correct insertion plane 140 , 240 , 340 , the tool device 120 can become an insertion tool. For example, the memory card 102 is placed in the tool device 120 and the tool device 120 is located relative to a corresponding SMT connector 10 . The bottom of the tool frame members 130 move the free latches 12 outward, and by applying force to the insertion plane 140 , 240 , 340 via handle 196 relative to the fixed frame members 130 , the memory card 102 is put in place and is locked when the insertion plane 140 , 240 , 340 stops. At this point, the latches 12 may be locked onto memory card 102 . The insertion planes 140 , 240 , 340 are each configured with guide slots 168 to receive a corresponding circular protrusion 166 extending from one of the frame members 130 .
FIGS. 12-14 show three different sizes of the interchangeable insertion planes 140 , 240 , 340 . By fitting one of them in the same spot as the extraction plane 150 and removal of the lever arm 170 , the side edges of the memory card plane fit inside the interlocking teeth 194 on each frame member 130 and the bottom edge of the insertion plane 140 , 240 , 340 rests on top the memory card to transfer force during plugging.
In exemplary embodiments, the tool frame members 130 are created so that each part of the frame 130 is the same. By having an asymmetric design, upon mating of the two frame members 130 , the sides the tool device 120 becomes symmetric and may also have more intricate design features (e.g., interlocking friction teeth 194 ).
In sum, by removing the lever arm 170 and replacing the extraction plane 150 with an appropriate insertion plane 140 , 240 , 340 , the tool device 120 can be assembled as an insertion tool. This is accomplished by placing the desired DIMM 102 into the tool device 120 , locating the tool device 120 using the node combs 110 built into the node frame (or temporarily disposed thereat), and engaging the tool device 120 by applying pressure to the insertion plane 140 , 240 , 340 . The DIMM 102 can then be locked in place by rotating the latches into a locked position which allows the interlocking friction teeth 194 of the tool device 120 to be pulled from the DIMM 102 .
Once the memory card 102 is inserted into the socket 10 , the insertion tool device 120 may be disengaged or removed from the memory card 102 . Alternatively, the insertion tool device 120 may remain coupled to the memory card 102 for future use. The same is true for the tool guide 110 , as discussed above.
From the above described exemplary embodiments, the following attributes of the present invention are disclosed. The invention relates to the creation of an apparatus capable of extracting and inserting a DIMM memory card (e.g., single high, double high, or quad high) from a computer system. The apparatus impacts the simple, safe plugging and unplugging of the DIMM memory card without damage to the DIMM or surrounding hardware.
In particular, the present disclosure describes an apparatus capable of releasing DIMM SMT latches. By releasing the DIMM SMT latches, the DIMM memory card is released from the SMT connector and supported by the tool frame of the apparatus for removal from the system. This is accomplished by a squeezing action between a top handle portion of the tool frame and a handle portion of the sliding extraction plane, which is in operable communication with a lever arm causing the lever arm to rotate. Rotation of the lever arm, which is in operable communication with a corresponding SMT latch in turn, disengages the SMT latches.
Replacing and removing features of the apparatus allows it to be converted into an insertion tool. In this insertion application, the DIMM memory card is held within the tool frame and upon location of the SMT joint, with or without the aid of a guide feature of the apparatus, can be engaged in the system.
The apparatus described in the above exemplary embodiments accurately locates, disengages and supports the DIMM memory card, or other similar expensive hardware, upon insertion and extraction, as well as locates and engages an SMT connector and latches thereof upon insertion of the tool frame, thus eliminating problems associated with the plugging and unplugging of this expensive hardware. In addition to making insertion and extraction of the DIMM memory card more efficient, the present invention provides for a more ergonomic apparatus for operators.
While the preferred embodiments to the invention has been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements which fall within the scope of the claims which follow. These claims should be construed to maintain the proper protection for the invention first described.
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An apparatus for extracting and inserting a circuit card into a socket, the apparatus includes a tool device releasably mountable to opposing sides defining the circuit card. The tool device includes a pair of frame members having a friction fit feature for attachment to the opposing side edges defining the circuit card; and a sliding plane translatable between the pair of frame members. Upward translation of the sliding plane relative to the fixed pair of frame members acts to release latches on the connector to extract the circuit card from the connector upon upward translation of the pair of frame members, and downward translation of the sliding plane relative to the fixed pair of frame members acts to transfer a force to the circuit card, thereby inserting the circuit card with the connector. The apparatus further includes a tool guide having two members opposing each other, each member including a plurality of slots, each configured to guide a respective edge of the tool device therethrough for alignment with the connector.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to patent application Ser. Nos. __/___,___, __/___,___, __/___,___, __/___,___, and __/___,___, respectively entitled “Image Processor Circuits. Systems, and Methods” having inventors Sandra Marie Johnson, Shih-Chung Chao, Nadi Rafik Itani, Caiyi Wang, Brannon Craig Harris, Ash Prabala, Douglas R. Holberg, Alan Hansford, Syed Khalid Azim, and David R. Welland; “Digital Camera Signal Processor and Method” having inventors Syed Khalid Azim, Shih-Chung Chao, Brannon Craig Harris, and Ash Prabala; “Pipelined Analog-to-Digital Converter (ADC) Systems. Methods. and Computer Program Products” having inventors Sandra Marie Johnson and David R. Welland; “High Voltage Input Pad System and Method” having inventors Douglas R. Holberg, Nadi Rafik Itani, and David R. Welland; and “Histogram-Based Automatic Gain Control Method and System for Video Applications” having inventors Nadi Rafik Itani, Caiyi Wang, and David R. Welland; each of these applications filed on even date herewith, and each incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to automatic gain control and more particularly to automatic gain control in hybrid analog and digital camera and imaging systems.
[0004] 2. Description of Related Art
[0005] Conventionally, gain control in camera and imager devices and systems is subject to considerable technical limitations which make it difficult to use current cameras for professional and consumer applications. In particular, gain control is undertaken with an analog system or with a digital system, lacking integrated controls which are effective for both the analog as well as the digital portions of a combined camera system. There is a need to separately control gain over the analog and digital subsystems.
SUMMARY OF THE INVENTION
[0006] According to the present invention, a signal processing system (SPS) for an imager device having a settable shutter includes a digital gain circuit, an analog gain circuit, a shutter gain circuit, and an automatic gain control (AGC) circuit, for controlling the digital, analog, and shutter gain blocks. According to the present invention, gain control of a signal processing system for an imager device includes an automatic gain control (AGC) circuit for controlling multimode levels of gain provided to selected gain modules of the camera system. According to one embodiment of the present invention, an automatic gain control (AGC) circuit includes a gain splitter circuit for receiving gain values which have been determined. The gain splitter circuit produces distributed gain values from the received gain values. The distributed gain values include shutter gain values for an imager device or CCD camera, as well as analog or VGA gain values, and digital gain values. According to another embodiment of the present invention, the AGC circuit provides at least a minimum level of chip gain, which is settable, and which is then divided into analog or VGA gain values and digital gain values. According to another embodiment of the present invention, the AGC circuit provides selectable threshold multimode gain control according to which chip gain values are provided between a user-selectable minimum gain value and a maximum level which is user-selectable. According to the present invention, the total gain is continuous across the thresholds of minimum shutter gain and minimum chip gain. Gain change according to the present invention is incremental according to predetermined gain step sizes. As total gain is increased beyond the user-established maximum shutter gain value, the incremental change in gain is performed in substantially the same gain step sizes. Accordingly, subsequent gain increases beyond the shutter maximum gain is accomplished with another gain mode, i.e., the analog or VGA gain mode, and remains user-transparent or invisible. Similarly according to the present invention, as total gain is increased beyond the maximum analog or VGA gain value, the incremental change in gain is performed in substantially the same gain step sizes. Accordingly, subsequent gain increases beyond the analog or VGA maximum gain are accomplished with another gain mode, i.e., the digital gain, and remains user-transparent or invisible. Shutter gain according to the present invention accordingly can be increased monotonically from zero to a user-settable shutter gain level threshold. The total maximum gain is additionally user-settable, and if the current automatic gain level exceeds the shutter gain maximum, the excess thereover is provided as chip gain, beyond any already established or set minimum chip gain level. Similarly, if the current automatic gain level exceeds the sum of the shutter gain maximum and the analog or VGA gain maximum, then additional gain is provided as digital chip gain up to a user-settable total maximum gain. According to the present invention, total chip gain is increasable substantially continuously without breach, in predetermined level steps across mode thresholds at which gain continues to progress, beyond which one or more particularized gain types cannot increase.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1A is a block diagram of an automatic gain control circuit according to the present invention;
[0008] [0008]FIG. 1B is a circuit diagram of a CDS/VGA circuit (CC) according to one embodiment of the present invention;
[0009] [0009]FIG. 1C is a graph of a typical waveform of VIN as a function of time which can be received from a CCD camera;
[0010] [0010]FIG. 2 is a block diagram of a digital gain control circuit according to one embodiment of the present invention;
[0011] [0011]FIG. 3 is a block diagram of a camera system connected to an analog image processing system (AIPS) which is configured according to the present invention;
[0012] [0012]FIG. 4 is a diagram of gain control versus light intensity for shutter gain and chip gain according to the present invention;
[0013] [0013]FIG. 5A is a block diagram of an automatic gain control circuit for an analog data processing subsystem according to another embodiment of the present invention;
[0014] [0014]FIG. 5B is a block diagram of first and second splitters according to one embodiment of the present invention;
[0015] [0015]FIG. 5C is a diagram of AGC gain according to one embodiment of the present invention, showing a first gain division between chip and shutter gain;
[0016] [0016]FIG. 5D is a diagram of chip gain according to one embodiment of the present invention, showing a second gain division, i.e., the division between analog (VGA) gain and digital gain;
[0017] [0017]FIG. 6 is a histogram used in an automatic gain control circuit according to the present invention, for one frame of pixel data produced by an imager system;
[0018] [0018]FIG. 7 is an image representation of multiple gain control windows according to the present invention;
[0019] [0019]FIGS. 8A and 8B are respective diagrams of CCD output level as a function of gain under different saturation conditions, in accordance with the present invention;
[0020] FIGS. 9 A- 9 D are a plurality of diagrams of gain in dB as a function of digital gain code for minimum chip gain and maximum shutter gain conditions according to the present invention;
[0021] [0021]FIG. 10 is a diagram of gain with a flickerless setting having hysteresis in accordance with operation according to the present invention;
[0022] [0022]FIG. 11 is a block diagram of an AGC control loop line decoder (ACLLD) according to one embodiment of the present invention; and
[0023] [0023]FIG. 12 is a flow diagram of the loop controller logic used by an ACLLD according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Referring now to Figure 1 A, there is shown a block diagram of an analog image processing system (AIPS) 113 including an automatic gain control (AGC) controller circuit 119 for controlling a correlated double/sample variable gain amplifier (CDS/VGA) circuit 114 and digital gain circuit 117 . Digital gain circuit 117 is connected at its input to analog-to-digital converter (ADC) 116 and at its output to formatter 118 . AIPS 113 additionally includes an analog clock generator circuit 120 , a timing generator circuit 121 , a phase lock loop (PLL) circuit 122 , and an I2C bus interface circuit 123 . AGC controller circuit 119 controls digital gain circuit 117 and CDSVGA circuit 114 and the timing for OFD pulses (shutter gain). PLL circuit 122 contributes to control of analog clock generator circuit 120 . Timing generator circuit 121 provides timing signals to formatter circuit 118 .
[0025] Referring now to FIG. 1B, there is shown a circuit diagram of a CDS/VGA circuit (CC) 114 according to the present invention. In particular, CC 114 includes first and second series connected amplifiers respectively 129 and 130 , first through fourth capacitors respectively 131 - 134 and C 1 -C 4 , and first and second switches respectively 135 and 136 which open and close according to clock signals respectively (φ 1 and φ 2 in order to obtain a correlated sample of an input waveform VIN which is shown in more detail in FIG. 1C. More particularly, according to one embodiment of the present invention, capacitor C 1 is connected to the input of amplifier 129 which in turn is connected at its output to capacitor 133 which in turn is connected to the input of amplifier 130 . Amplifier 129 is connected in parallel with capacitor 132 and switch 135 . Similarly, amplifier 130 is connected in parallel with capacitor 134 and switch 136 . According to another embodiment of the present invention, capacitors 132 and 133 are variably settable with an analog (VGA) gain signal from AGC controller 119 .
[0026] Referring now to FIG. 1C, there is shown a graph of a typical waveform of VIN as a function of time which can be received from a CCD camera. In particular, the typical form of VIN includes first through third levels respectively L1-L3. Correlated double sampling permits sampling of a difference between levels L2 and L3 to eliminate the noise which is shared at the two levels.
[0027] Referring now to FIG. 2, there is shown a block diagram of a digital gain circuit 117 according to one embodiment of the present invention. Digital gain circuit 117 according to one embodiment includes a read-only-memory (ROM) 171 , a multiplier 172 , and a clipper circuit 173 . ROM 171 stores selected gain values for use as a multiplicand by multiplier 172 . ROM 171 is connected to multiplier 172 which in turn is connected to clipper circuit 173 . The digital gain is used in conjunction with the analog gain provided through CDS/VGA 114 to supply a substantial controllable range of automatic gain adjustment. According to one embodiment of the present invention, the digital gain portion of the AGC is engaged only after the analog gain has been employed and an additional level of gain is desired. According to one embodiment of the present invention, the digital gain is engaged after the entire analog gain has been deployed. Digital gain provides an additional 0 to 18 dB of gain at 0.074 dB gain steps.
[0028] Referring now to FIG. 3, there is shown a block diagram of a camera system 180 connected to an analog image processing system (AIPS) 113 which is configured according to the present invention. The imager signal is subject to external gain applied through the shutter speed setting of the camera system 180 , through an analog internal chip gain provided by CDS/VGA 114 , and through digital gain circuit 117 . A selected image is input to camera system 180 , where a 60 dB gain adjustment potential can be exercised by changing the shutter speed of camera system 180 . This 60 dB range is applied when there is too much light. The gain brings the video level to a good operating range. The input signal from CCD system 180 goes to a correlated double sample/variable gain amplifier (CDS/VGA) circuit 114 where low frequency noise is removed and a selected analog gain level is applied. The signal is then subject to a chip gain in a range up to approximately 38 dB in the CDS/VGA circuit 114 and digital gain circuit 117 . This gain is used to boost dark images to a proper signal level. After a received signal is digitized by ADC 176 , it is applied through an AGC control circuit 119 to set a selected level of gain according to the present invention, in analog and/or digital gain portions. The total digital gain range applicable by digital gain circuit 117 is about 18 dB according to one embodiment. The total gain range of the chip and shutter is approximately 90 dB, which is enough to cover a substantial range of lighting conditions indoors and outdoors, as well as physical and hardware variations.
[0029] Formatter circuit 118 according to the present invention takes the ADC output, clips received data to a range from binary “0000 0001 00” to binary “111 1110 11” and adds special end-of-video (EAV) and start-of-video (SAV) codes to each video line according to the present invention. The output of formatter circuit 118 is available at the pins DOUT<9:0>, causing transitions to be made at the falling edges of the pixel rate clock CLKO. Timing block circuit 181 causes CCD system 180 to shift data out during successive horizontal line periods. The data provided is shifted from the horizontal shift register of CCD system 180 at the imager output pin, one pixel at a time. Timing circuit 181 creates the required driving signals to control the timing operations of CCD system 180 . The timing signals particularly enable shifting data out of CCD system 180 are H 1 , H 2 [=not(H 1 )], and FR.
[0030] Referring now to FIG. 4, there is shown a diagram of gain control versus light intensity for shutter gain and chip gain according to the present invention. In particular, a graph of an automatic gain control method according to the present invention shows a predetermined level of gain is applied by AGC control circuit 119 acting selectively through timing block circuit 181 upon CCD system 180 , CDSVGA circuit 114 , and digital gain circuit 117 , to establish selected gain levels at a given light intensity. Gain is applied in the following order for light intensity varying from low to high: first with shutter gain to the extent possible, in incremental steps, for example, and then with chip gain applied through CDS/VGA circuit 114 and digital gain 117 . According to the present invention, gain is applied by first and second gain steps by using up the gain in the block closest to the input first (shutter gain) and then proceeding to a next gain block (the chip gain) once the complete shutter gain has already been applied. This improves the signal to noise ratio (SNR) according to the present invention. According to one embodiment of the present invention, the gain is split between both blocks seamlessly to ensure that the end of one gain region coincides with the beginning of the next gain region, and according to one embodiment each gain block has approximately equal gain steps.
[0031] Referring now to FIG. 5A, there is shown a block diagram of an automatic gain control (AGC) circuit 119 according to one embodiment of the present invention. In particular, AGC circuit 119 includes a multiplexer (MUX) 191 configured to receive input mosaic pixel values and luminance pixel values subject to control line settings of a signal line MOSAIC, permitting selection of whether mosaic pixel values or luminance pixel values are to be provided to histogram circuit 192 . AGC circuit 119 further includes a histogram circuit 192 subject to control signals TARGET and AGC_WIN, an error circuit 193 connected to histogram circuit 192 , a summation element 194 connected to error circuit 193 , a clip circuit 195 connected to summation element 194 , a unit delay element 196 connected to the clip circuit 195 , and a splitter circuit 197 connected to the unit delay element 196 effective for producing a shutter gain signal and a chip gain signal to control relative gain settings according to the present invention. The output of unit delay element 196 provides a selected gain subject to a gain input provided from clip circuit 195 subject to explicitly written override values AGC_GAIN_WR. AGC circuit 119 receives pixel values of either mosaic or luminance style and generates a histogram of the received data for successive full frames according to the present invention. Based on the contents of the histogram, image brightness levels to be selected are determined, causing an AGC value to be incremented, decremented, or left unchanged for each frame. Histogram circuit 192 stores frame data into histogram bins as discussed further below. Error circuit 193 takes the histogram information and generates an error code that either increments or decrements or does not change the output AGC gain value. Summing element 194 accumulates the AGC value in view of an error signal from error circuit 193 , and clip circuit 195 clips the result to insure that it is within a predetermined gain range. Splitter circuit 197 takes received gain values and distributes them to an appropriate gain block including shutter and chip gain circuits.
[0032] Referring now to FIG. 5B, there is shown a block diagram of first and second splitters according to one embodiment of the present invention. In particular, first splitter 197 divides input received gain values and produces shutter gain values and chip gain values. The chip gain value is provided in code form to second splitter 198 to produce a digital gain code value and an analog (VGA) gain code value for each received chip gain value produced by first splitter.
[0033] Referring now to FIG. 5C, there is shown a diagram of AGC gain according to one embodiment of the present invention, showing a first gain division between chip and shutter gain. The AGC circuit 119 sends a gain code to the first splitter 197 , which is between the maximum and minimum chip values. First splitter 197 operates by determining whether the AGC gain is above or below a gain division 1. If the AGC gain is below gain division 1, than the shutter gain is set to a gain value between maximum shutter gain and minimum shutter gain that corresponds to the AGC gain code. The chip gain for the case in which the AGC gain is below division 1 is set to minimum chip gain. When the AGC gain is above gain division 1, the chip gain is set to a gain value between minimum chip gain and maximum chip gain that corresponds to the AGC gain. The shutter gain, for the case in which AGC gain is above the gain division 1, is set to maximum shutter gain. Incremental changes in AGC gain below gain division 1 cause shutter gain to change at a certain rate of shutter gain to AGC gain code, while the chip gain is held constant. Incremental changes in the gain of the AGC above gain division 1 cause the chip gain to change at a predetermined rate of chip gain to AGC gain code, while the shutter gain is held constant. In one case according to the present invention, maximum shutter gain, minimum chip gain, and maximum chip gain are all programmable or user settable values. Changing these values will alter the operational characteristic between the transition point at which the shutter gain changes its slope from some gain rate to zero, and where the chip gain changes from a slope of zero to some positive gain rate always occurs at gain division 1. The rate of change in the shutter gain and the rate of change in the chip gain are approximately equal according to one embodiment of the present invention. This causes the crossing over of gain division 1 to be seamless, continuous, and unnoticed by the user.
[0034] Referring now to FIG. 5D there is shown a diagram of chip gain according to one embodiment of the present invention, showing a second gain division, i.e., the division between analog (VGA) gain and digital gain. The first splitter 197 sends a second gain code (i.e., a chip gain code) to the second splitter 198 which is between maximum and minimum chip gain values. Second splitter 198 operates by determining whether the chip gain is above or below a second gain division 2. If the gain is below gain division 2, then the VGA gain is set to a value between minimum VGA gain and maximum VGA gain that corresponds to the chip gain code. The digital gain, for the case in which the gain is below gain division 2, is set to minimum digital gain. When the VGA gain is above gain division 2, the digital gain is set to a gain value between minimum digital gain and maximum digital gain that corresponds to the chip gain. The VGA gain, for the case in which the chip gain is above gain division 2, is set to maximum VGA gain. Incremental changes in chip gain below gain division 2 cause the VGA gain to change at a certain rate of VGA gain to chip gain code, while the digital gain is held constant. Incremental changes in the chip gain above gain division 2 cause the digital gain to change at a predetermined rate of digital gain to chip gain code, while the AGC gain is held constant. In one case according to one embodiment of the present invention, maximum VGA gain, minimum VGA gain, maximum digital gain, and minimum digital gain are each programmable or user settable values. Changing these values will alter the operational characteristic between the transition point where the VGA gain changes its slope from some gain rate to zero, and where the digital gain changes from a slope of zero to some positive gain rate always at gain division 2. The rate of change in the VGA gain and rate of change in the digital gain are approximately equal according to one embodiment of the present invention. This causes the crossing over of gain division 2 to be seamless, continuous, and unnoticed by the user. Note that maximum VGA gain+maximum digital gain=maximum chip gain, and minimum VGA gain+minimum digital gain=minimum chip gain.
[0035] Referring now to FIG. 6, there is shown a diagram of a histogram according to one embodiment of the present invention. Data from each frame captured by the camera system is categorized into particular bins of the histogram according to brightness level. Six explicit bins and one implicit bin are included. The applicable fixed value needed to increment each bin is shown below the chart. The target level a bin needs to exceed for a particular output of the histogram block is programmable through a target level register. The output of histogram circuit 192 is a 7 bit word, where only one bit is high, indicating the highest level bin that exceeds a target level. According to one example, a count of 0000100 indicates bin 1 is the highest level bin above the threshold.
[0036] Table 5 below is a diagram showing error signal generation by error circuit 193 according to the present invention. A 7 bit code is produced from histogram circuit 192 , corresponding to one of the seven bins provided according to one embodiment of the present invention. From this, an appropriate error code is chosen and multiplied by a speed factor. The value of slew and speed are programmable. The slew value establishes the recovery speed from a very bright picture that saturated the output of the ADC.
TABLE 5 ERROR CODE GENERATION Bin Error Error Output Bin 5 SLEW Error x (Speed Multiplier) Bin 4 −2 Bin 3 −1 Bin 2 0 Bin 1 1 Bin 0 4 Bin X 16
[0037] One of three AGC windows can be selected through associated register according to one embodiment of the present invention. In particular, a full AGC window, a ¼ full AGC window, and a {fraction (1/16)} full AGC window can be selected. Changing the area upon which AGC adjustments are applied permits better scene selection according to the present invention. Maximum gain, minimum chip gain, and maximum shutter gain are programmable according to the present invention. The user selects maximum gain to cause a scene to go dark at a certain low light level rather than gaining up to a noisy image. A minimum chip gain level prevents the output of the camera system from becoming saturated by the time the shutter gain is supposed to be active. If the output of the imager saturates, the shutter gain will never be engaged and particular bright scenes will be lost.
[0038] Referring now to FIG. 7, there is shown an image representation of multiple gain control windows according to the present invention. More particularly, FIG. 7 is a picture of multiple automatic gain control windows which are settable according to the present invention. One of three AGC windows can be selected through an associated register according to one embodiment of the present invention. In particular, a full AGC window, a ¼ full AGC window, and a {fraction (1/16)} full AGC window can be selected. Changing the area upon which AGC adjustments are applied permits better scene selection according to the present invention.
[0039] Referring now to FIGS. 8A and 8B, there are shown respective diagrams of CCD output level as a function of gain under saturation conditions, in accordance with the present invention. In particular, FIG. 8A is a diagram of operable gain operation according to the present invention, where minimum gain is set to prevent CCD camera system saturation. FIG. 8B is a diagram of an erroneous gain setting for minimum chip gain which causes the CCD camera system to saturate. On the other hand, FIG. 8A is a diagram of CCD output voltage level versus light intensity in operation according to the present invention, in which a level of minimum gain is set so that the CCD does not saturate.
[0040] Referring now to FIGS. 9 A- 9 D, there are shown a plurality of diagrams of gain in dB as a function of gain codes for minimum chip gain and maximum shutter gain conditions according to the present invention. In particular, FIGS. 9 A- 9 D show how clipper circuit 95 limits the range of accumulator code according to the present invention, and how splitter circuit 97 distributes gain to applicable gain blocks according to the present invention. Specifically, FIG. 9A shows the result of minimum gain and maximum shutter gain set to 0. Without gain restrictions, there are 765 or 784 codes of shutter gain, depending upon whether the camera follows a NTSC or a PAL standard. The dark vertical lines indicate selected clipping values used by clipper circuit 95 . There are two minimum clip values, depending upon whether an NTSC or a PAL camera is used. A maximum clip value is set according to one embodiment of the present invention by setting a maximum gain value with register 2CH, and this is 484 for the maximum gain range setting. In FIG. 9B, there is shown a restriction on the minimum gain (Min_Gain), but there is no restriction on the maximum shutter gain. The maximum chip value is still set by Max Gain as before. A seamless division of gain occurs with the transition between shutter gain and analog gain occurring at Min_Gain. According to FIG. 9C, there is no minimum gain restriction, and the maximum shutter gain is set to Max_Shutt. As a result, the minimum clip value has been increased by Max_Shutt, and the shutter gain range has been decreased. In FIG. 9D, restrictions have been placed on minimum gain (Min_Gain) and maximum shutter gain (Max_Shutt). The plot shows characteristics of both case 2 and case 3. The minimum clip value has now moved to the right by Min_Gain+Max_Shutt, and the transition between shutter gain and analog gain occurs at Min_Gain. The value Max Gain still sets the maximum clip value. Each of FIGS. 9 A- 9 D shows shutter gain increasing from zero to a maximum level which it does not exceed. In the case of FIGS. 9B and 9C, a non-zero level of minimum chip gain is set. Accordingly, when shutter gain is zero, a total gain equal to the minimum chip gain is produced. The analog gain (or VGA gain) similarly has a maximum value which it cannot exceed. Accordingly, if the desired total gain exceeds the maximum shutter gain combined with the maximum analog gain, then the analog gain levels off (the shutter gain will already have leveled off), leaving all additional gain to be provided as digital gain, until a maximum gain point is reached. The threshold points at which additional gain is provided from another gain source are continuous, without abrupt notice to the user, according to the present invention.
[0041] Referring now to FIG. 10, there is shown a diagram of gain with a flickerless setting having hysteresis in accordance with operation according to the present invention. In particular, FIG. 10 is a diagram of gain as a function of gain code with a flickerless setting established which includes a hysteresis loop. Flickerless modes are included according to the present invention to enable indoor operation with fluorescent lights. If the fluorescent lighting flickers at twice the frequency of the power supply frequency, it is averaged upon receipt by the camera system over an integer number of cycles to avoid flicker in the resulting video to be displayed. There are two possible flickerless settings for particular exposure times. One setting averages one cycle of the fluorescent lights and another averages two cycles of the fluorescent light. A hysteresis loop is used according to the present invention to prevent variations in gain from causing the shutter speed to jump back and forth between the one and two cycle settings. Such flickering would produce undesirable effects, since analog gain is difficult to set to match a 2× gain step exactly. Flickerless modes are possible for combinations of camera type (PAL or NTSC) and operation environments (PAL or NTSC). FIG. 10 shows a graphical representation of flickerless AGC operation according to the present invention.
[0042] The AGC control loop is selectively disabled according to the present invention and written to manually to circuit 96 along write input AGC_GAIN_WR. Writing to associated registers causes accumulator updating with a written value at the end of each frame. If the AGC loop is disabled by setting the associated register, the accumulator value changes will not occur until the loop is enabled or the accumulator is manually written to through associated registers. Once a new gain value is set, it is passed to splitter circuit 97 where appropriate gain values are established for shutter and chip gain according to the settings for minimum gain, maximum shutter gain, flickerless mode, PAL, and PAL environment.
[0043] Referring now to FIG. 11, there is shown a block diagram of an AGC control loop line decoder (ACLLD) 890 according to one embodiment of the present invention. In particular, ACLLD 890 includes a shutter gain adjustment circuit (SGAC) 901 , a loop controller 902 , read-only-memory (ROM) 903 , and a 20-bit shift register (SR) 904 . SGAC 901 receives input values of shutter gain, and makes a PAL or NTSC adjustment to produce an adjusted shutter gain (ASG) which is also referred to as a shutter gain adjusted value. In particular, SGAC 901 adds the amount of 55 to each input value received according to the PAL standard, or adds 74 to each input shutter gain value received according to the NTSC standard. Input shutter gain values range from zero (0) to 765 according to the NTSC standard. Input shutter gain values range from zero (0) to 784 according to the PAL standard. The value of zero (0) in terms of input shutter gain values represents full exposure. Accordingly, by adding 55 or 74, depending upon the standard selected, an adjusted shutter gain level conforming either to PAL or NTSC is achieved. SGAC 901 is connected to loop controller 902 to provide an adjusted shutter gain level which is then converted into a form which specifies a number of lines and a fraction of a line. Loop controller 902 defines predetermined loop variables including a shift index value (SIV) “i” and a decremented ASG value (DASG) which has been reduced by 77 a number of “i” times, i.e., “x.” The variable “i” is initially set to zero, while the value of “x” is decremented by loop controller 902 by a number of times the decrementation factor 77 is exceeded by the initial ASG value. The decremented value of “x”, i.e., DASG, is provided by loop controller 902 to ROM 903 as an entry to produce a corresponding 12-bit output code, which is provided to shift register 904 . The 12-bit code is shifted “i” times, based upon the final value of “i” which is produced after decrementation of “x” has been completed. Accordingly, SR 904 produces a 9-bit output defining a number of lines and an 11-bit output defining a fraction of a line, for each input 12-bit address. The ROM codes in ROM 903 establish predetermined exposure settings, so that predetermined flickerless modes can be accessed with applicable shutter gain values. ACLLD 890 implements according to one embodiment of the present invention a predetermined gain step size of 0.087 dB, which equals 6 dB/77. Since the number of lines of exposure is a factor of 2 smaller each 77 gain steps, a 77 code ROM 903 coupled to shift register 904 suffices to represent all desired gain values.
[0044] [0044]FIG. 12 is a flow diagram of the loop controller logic used by ACLLD according to one embodiment of the present invention. In particular, flow diagram 919 includes initially setting 930 a shift index value “i” equal to zero for a particular adjusted shutter gain (ASG) “x” (i.e., “shutter gain adjusted”). Next, a determination is made 931 (i.e., test 931 ) according to one embodiment of the present invention as to whether the value of the ASG is greater than or equal to a particular predetermined value, such as for example 77 in this case. If yes, the ASG is decremented 932 by the predetermined resolution value and test 931 is repeated. In addition to decrementing the ASG, the index value i is incremented by one integer value, permitting the number of times the ASG exceeds 77 to be tracked as an index of the amount of shift that should be applied by shift register 904 upon receipt of the resultant decremented ASG value, which will be an integer from zero to 76.
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A selectable threshold multimode gain control apparatus and method for a charge coupled device (CCD) or CMOS imaging system includes an automatic gain control (AGC) circuit which continuously controls gain in said CCD system to produce a mutually continuous combined target gain level. A processing system for an imager device includes a camera system for producing an imager signal, a correlated double sample (CDS) circuit for receiving data from an imager, a variable gain amplifier (VGA), an analog-to-digital converter (ADC) coupled to said CDS circuit, a digital gain circuit (DGC) coupled to said ADC, and an automatic gain control (AGC) circuit coupled to said DGC for controlling the CDS circuit and the DGC, as well as shutter timing for shutter gain.
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This is a divisional application of copending application Ser. No. 07/234,790, filed on Aug. 19, 1988, now issued as U.S. Pat. No. 4,960,902.
BACKGROUND OF THE INVENTION
a. Field of Invention
This invention relates to novel indole derivatives, and to the processes for their preparation and use.
Notwithstanding the advances made during the last four decades in the development of agents for the treatment of inflammatory conditions and for analgesic purposes in conditions which require relief from pain in a mammal, there still remains a need for effective agents without the side effects associated with the therapeutic agents presently used for these purposes.
More specifically, this invention relates to tricyclic acetic acid derivatives in which the tricyclic portion thereof is characterized by having an indole portion fused to a pyrano ring. Still more specifically, the compounds of this invention are characterized as derivatives of the following tricyclic acetic acid system: ##STR1## 1,3,4,9-tetrahydropyrano[3,4-b]indole-1-acetic acid in which the carbon at the 1-position is further substituted with an alkyl group and the 5-, 6-, 7-, or 8-positions is further substituted with a trifluoromethoxy group.
The indole derivatives of this invention have been found to exhibit useful pharmacodynamic properties without eliciting undersirable side effects. Notable attributes of this effect are anti-inflammatory and analgesic activities.
b. Prior Art
The closest prior art to the present invention is:
Demerson et al, U.S. Pat. No. 3,939,178. Demerson et al disclosed 1,3,4,9-tetrahydropyrano[3,4-b]indoles and 1,3,4,9-tetrahydrothiopyrano[3,4-b]indoles having analgesic and anti-inflammatory activity but not with the substituents of the present invention.
SUMMARY OF THE INVENTION
The compounds of this invention are represented by formula (I) ##STR2## wherein R is trifluoromethoxy; R 1 is hydrogen or 3-oxo-1-isobenzofuranyl, and the pharmaceutically acceptable salts thereof, when R 1 is hydrogen.
The preferred compounds of the present invention are designated
1-ethyl-1,3,4,9-tetrahydro-7-(trifluoromethoxy)pyrano[3,4-b]indole-1-acetic acid;
1-ethyl-1,3,4,9-tetrahydro-5-(trifluoromethoxy)pyrano[3,4-b]indole-1-acetic acid;
1-ethyl-1,3,4,9-tetrahydro-8-(trifluoromethoxy)pyrano[3,4-b]indole-1-acetic acid;
1-ethyl-1,3,4,9-tetrahydro-6-(trifluoromethoxy)pyrano[3,4-b]indole-1-acetic acid and the pharmaceutically acceptable salts thereof.
Also preferred is the ester designated
1-ethyl-1,3,4,9-tetrahydro-7-(trifluoromethoxy)pyrano[3,4-b]indole-1-acetic acid 3-oxo-1-isobenzofuranyl ester.
The indole derivatives of this invention of formula (I) are prepared by the following processes.
PROCESS A ##STR3## wherein R is trifluoromethoxy.
PROCESS B ##STR4## wherein R is trifluoromethoxy.
DETAILED DESCRIPTION OF THE INVENTION
The term "lower alkyl" as used herein represents straight chain alkyl radicals containing 1 to 4 carbon atoms and branched chain alkyl radicals containing three to four carbon atoms and includes methyl, ethyl, propyl, isopropyl, butyl, isobutyl and the like.
The term "halogen" as used herein includes fluorine, chlorine, bromine and iodine.
The compounds of formula (I) form salts with suitable pharmaceutically acceptable inorganic and organic bases. These derived salts possess the same activities as the parent acid and are included within the scope of this invention. The acid of formula (I) is transformed in excellent yield into the corresponding pharmaceutically acceptable salts by neutralization of said acid with the appropriate inorganic or organic base. The salts are administered in the same manner as the parent acid compounds. Suitable inorganic bases to form these salts include, for example, the hydroxides, carbonates, bicarbonates or alkoxides of the alkali metals or alkaline earth metals, for example, sodium, potassium, magnesium, calcium and the like. The preferred salt is the sodium salt. Suitable organic bases include the following amines; lower mono-, di- and tri-alkylamines, the alkyl radicals of which contain up to three carbon atoms, such as methylamine, dimethylamine, trimethylamine, ethylamine, di- and triethylamine, methylethylamine, and the like; mono, di- and trialkanolamines, the alkanol radicals of which contain up to three carbon atoms, such as mono-, di- and triethanolamine; alkylenediamines which contain up to six carbon atoms, such as hexamethylenediamine; amino sugars, such as glucosamine; cyclic saturated or unsaturated bases containing up to six carbon atoms, such as pyrrolidine, piperidine, morpholine, piperazine and their N-alkyl and N-hydroxyalkyl derivatives, such as N-methylmorpholine and N-(2-hydroxyethyl)piperidine, as well as pyridine. Furthermore, there may be mentioned the corresponding quaternary salts, such as the tetraalkyl (for example tetramethyl), alkyl-alkanol (for example methyltrimethanol and trimethyl-monoethanol) and cyclic ammonium salts, for example the N-methyl-pyridinium, N-methyl-N-(2-hydroxy-ethyl)-morpholinium, N,N-dimethyl-morpholinium, N-methyl-N-(2-hydroxyethyl)-morpholinium, N,N-dimethyl-piperidinium salts, which are characterized by good water-solubility. In principle, however, there can be used all the ammonium salts which are physiologically compatible.
The transformations to the salts can be carried out by a variety of methods known in the art. For example, in the case of salts of inorganic bases, it is preferred to dissolve the acid of formula (I) in water containing at least one equivalent amount of a hydroxide, carbonate, or bicarbonate. Advantageously, the reaction is performed in a water-miscible organic solvent inert to the reaction conditions, for example, methanol, ethanol, dioxane, and the like in the presence of water. For example, such use of sodium hydroxide, sodium carbonate or sodium bicarbonate gives a solution of the sodium salt. Evaporation of the solution or addition of a water-miscible solvent of a more moderate polarity, for example, a lower alkanol, for instance, butanol, or a lower alkanone, for instance, ethyl methyl ketone, gives the solid salt if that form is desired.
To produce an amine salt, the acid of formula (I) is dissolved in a suitable solvent of either moderate or low polarity, for example, ethanol, acetone, ethyl acetate, diethyl ether and benzene. At least an equivalent amount of the amine corresponding to the desired cation is then added to that solution. If the resulting salt does not precipitate, it can usually be obtained in solid form by addition of a miscible diluent of low polarity, for example, benzene or petroleum ether, or by evaporation. If the amine is relatively volatile, any excess can easily be removed by evaporation. It is preferred to use substantially equivalent amounts of the less volatile amines.
Salts wherein the cation is quaternary ammonium are produced by mixing the acid of formula (I) with an equivalent amount of the corresponding quaternary ammonium hydroxide in water solution, followed by evaporation of the water.
Also included in this invention are the optical isomers of the compounds of formula (I) which result from asymmetric centers, contained therein e.g. 1-carbon. Such isomers can be obtained in substantially pure form by classical separation techniques and by stereochemically controll syntheses. Included is the specific case of the resolution of 1-ethyl-1,3,4,9-tetrahydropyrano[3,4-b]indole-1-acetic acids into their optical isomers by separation of the corresponding [(IS)-endo]-1,7,7-trimethyl-bicyclo[2.2.1]heptan-2-yl esters followed by basic hydrolysis.
ANTI-INFLAMMATORY ACTIVITY
The useful anti-inflammatory activities of the pyranoindole acetic acid derivatives of formula (I) are demonstrated in standard pharmacologic tests, for example, the test designated: Preventative Adjuvant Edema
The objective of this test is to determine the ability of test drugs to exhibit an acute anti-inflammatory effect in rats. This test is a primary screen for anti-inflammatory drugs.
Species:
Male Sprague Dawley rats (180-200 g) are used. The animals have free access to water but food is withdrawn 18 hours before testing.
Drug Preparations and Administration:
Freund's complete adjuvant is prepared by suspending 5 mg of killed and dried Mycobacterium butyricum (Difco) in 1 mL mineral oil. The test compounds are dissolved, or suspended in 0.5% Tween 80 in distilled water according to their solubility. For primary screening all drugs are administered by gastric gavage at the arbitrary dosage of 25 mg/kg, p.o. in a volume of 0.5 mL/100 g body weight to groups of 10 animals.
Methodological Details:
The method is essentially that described by Wax et al, J. Pharmacol. Exp. Ther., 192, 166-171 (1975). Groups of rats are injected intradermally in the left hind paw with 0.1 mL of Freund's complete adjuvant. The test compound or vehicle is administered immediately before the adjuvant, 24 hours and 48 hours after the adjuvant (days 0, 1 and 2). The injected hind paw volume is measured before the injection of adjuvant and 24 hrs. after the last drug administration (day 3) by means of a plethysmometer (Buxco Electronics Inc.). The difference between the hind paw volume on day 0 and day 3 represents the edema volume. Etodolac (25 mg/kg, p.o.) is included as a positive control.
Presentation of Results:
The mean edema volume (expressed as mL±SEM) is calculated for each group and the percentage protection conferred by the drug is calculated: ##EQU1## where c is the mean edema volume for the vehicle-treated (0.5% Tween 80 in distilled water) controls and t is the means edema volume for the drug treated group.
ANALGESIC ACTIVITY
A further test used to determine the utility of the compounds of the present invention is designated: Drug Effects on Phenylbenzoquinone-induced Writhing in Mice.
The objective of this test is to determine the ability of test drugs to inhibit the nociceptive (pain) response of mice injected with a chemical irritant. This test is a primary screen for both peripheral and centrally acting analgesic drugs.
Species:
Male Swiss albino mice (15-25 g). The animals are fasted for 18 hours prior to use but have free access to water.
Drug Preparation and Administration:
Drugs are dissolved or suspended according to their solubility in 0.5% Tween 80 in distilled water. They are administered by gastric gavage in a volume of 5 mL/kg. For primary screening all drugs are administered at the arbitary dosage of 10 mg/kg, p.o. to a group of 10 mice.
Methodological Details:
A modification of the method of Siegmund et al, Proc. Soc. Exp. Biol. Med., 95, 729-731 (1957) is used. Groups of 5 mice are dosed with the test compound or vehicle control. Sixty minutes later the animals are injected i.p. with 0.3 mL/20 g body weight of a 0.02% solution of phenylbenzoquinone (PBQ; 2-phenyl-1,4-benzoquinone) and placed in individual observation boxes. The number of writhing or abdominal squirming movements made by each mouse during the following 15 min. period is counted. The experiment is repeated with another group of 5 mice and the mean number of writhes per mouse for a group of 10 mice is calculated.
Presentation of Results:
Drug treated and vehicle-treated control groups are compared and the percentage protection conferred by the drug is calculated: ##EQU2## where c=mean number of writhes in the control group where t=mean number of writhes in the test drug group
ANTI-INFLAMMATORY EFFECT AGAINST ESTABLISHED EDEMA IN ADJUVANT ARTHRITIC RATS
An additional test used to determine the utility of the compounds of the present invention is designated: Curative Adjuvant Arthritis.
The objective of this test is to evaluate the ability of drugs to decrease edema in rats with established adjuvant arthritis in order to characterize further the anti-inflammatory activity of the compounds of the present invention.
Species
Male inbred Wistar Lewis rats with an initial body weight of 180-200 g were used. The animals had free access to food and water throughout the test.
Drug Preparations and Administration
Freund's Complete Adjuvant (FCA) was prepared by suspending 5 mg killed and dried Mycobacterium butyricum (Difco) in 1 mL mineral oil. The test compounds were dissolved, or suspended with a few drops of Tween 80, in distilled water according to their solubility. They were administered by gastric gavage in a volume of 0.5 mL/100 g body weight to groups of 10 animals at doses of 3 mg/kg/day p.o.
Methodological Details
Arthritis was induced in rats by intradermal injection of 0.1 mL FCA in the distal third of the tail (day 0). The volume of both hind paws were measured and body weight recorded at that time. On day 16 after FCA injection the volume of both hind paws were again measured. Only rats with consistent and well established arthritis were selected for further experimentation (i.e. an increase in volume of between 1.0 and 2.5 mLs for both hind paws and a difference between left and right hind paws no greater than 25%). Such animals were distributed into groups of 10 so that there was no significant difference in mean hind paw volume between groups. Mean body weight for each group was recorded. Drug or vehicle treatment was initiated on day 16. Animals were dosed daily from day 16 to day 25 (i.e. a total of 9 doses). The volume of both hind paws and the body weight of the animal was recorded 2 hours after the last drug administration. Vehicle treated arthritic animals acted as a vehicle-treated control group and animals treated with etodolac (3 mg/kg po) acted as a positive control group.
Presentation of Results
The results are expressed as a change in hind paw volume (mean of both hind paws) and a change in body weight from day 16 to day 25. The ED 50 , or dose which causes such an effect in 50% animals, is calculated by probit analysis.
Typical results obtained for the compounds of the present invention in the aforementioned tests are as follows:
TABLE I______________________________________ Preventative Adjuvant PhenylquinoneDrug Edema* Writhing in Mice*______________________________________1-ethyl-1,3,4,9-tetrahydro- 88 (25) 47 (10)7-(trifluoromethoxy)pyrano- 24[3,4-b]indole-1-acetic acidetodolac 68 (25) 168______________________________________ *The numbers quoted are either percent inhibition at the dose in mg/kg given in parentheses or the ED.sub.50 in mg/kg.
TABLE II__________________________________________________________________________Curative Adjuvant Arthritis Dose Injected Non-Injected Body Weight mg/kg/day Paw Edema Paw Edema ChangeDrug p.o. (mL) (mL) (g)__________________________________________________________________________Control -- +1.82 +2.46 -61-ethyl-1,3,4,9-tetrahydro- 0.3 +0.53 +1.21 +27-(trifluoromethoxy)pyrano- 1 -0.18 +0.35 +2[3,4-b]indole-1-acetic acid 3 -0.60 +0.11 +20etodolac 0.3 +1.12 +1.86 -3 1 +0.40 +1.14 -9 3 -0.28 +0.51 +10__________________________________________________________________________
In curative adjuvant arthritis, 1-ethyl-1,3,4,9-tetrahydro-7-(trifluoromethoxy)pyrano-[3,4-b]indole-1-acetic acid at 1 mg/kg/day produced an anti-inflammatory effect intermediate between that produced by 1 and 3 mg/kg etodolac. Accordingly, said compound is approximately 2-fold more potent than etodolac (Table II). In addition, animals treated with the highest dose of 1-ethyl-1,3,4,9-tetrahydro-7-(trifluoromethoxy)pyrano-[3,4-b]indole-1-acetic acid (3 mg/kg/day) appeared healthy as assessed by body weight gain.
The lack of side effects associated with the compounds of this invention are demonstrated by standard acute toxicity tests as described by R. A. Turner in "Screening Methods in Pharmacology," Academic Press, New York and London, 1965, pp. 152-163, and by prolonged administration of the compound to warm-blooded animals.
When the compounds of this invention are employed as anti-inflammatory and analgesic agents in warm-blooded animals, they are administered orally, alone or in dosage forms, i.e., capsules or tablets, combined with pharmacologically acceptable excipients, such as starch, milk sugar and so forth, or they are administered orally in the form of solutions in suitable vehicles such as vegetable oils or water. The compounds of this invention may be administered orally in sustained release dosage form or transdermally in ointments or patches. The compounds of this invention may also be administered in the form of suppositories.
The dosage of the compounds of formula (I) of this invention will vary with the particular compound chosen and form of administration. Furthermore, it will vary with the particular host under treatment. Generally, the compounds of this invention are administered at a concentration level that affords efficacy without any deleterious side effects. These effective anti-inflammatory and analgesic concentration levels are usually obtained within a therapeutic range of 1.0 μg to 500 mg/kg per day, with a preferred range of 1.0 μg to 100 mg/kg per day. The preferred anti-inflammatory and analgesic dose range is 20 μg to 20 mg/kg/day.
The compounds of this invention may be administered in conjunction with nonsteroidal anti-inflammatory drugs such as ibuprofen and aspirin, and/or with opiate analgesics such as codeine, oxycodone and morphine together with the usual doses of caffeine, or in combination with antihistamines, decongestants, and antitussives. When used in combination with other drugs, the dosage of the compounds of the present invention is adjusted accordingly.
The following examples further illustrate this invention.
EXAMPLE 1
1-Ethyl-1,3,4,9-tetrahydro-7-(trifluoromethoxy)-pyrano[3,4-b]indole-1-acetic Acid and 1-Ethyl-1,3,4,9-tetrahydro-5-(trifluoromethoxy)-pyrano[3,4-b]indole-1-acetic Acid
Process A
Step 1) Preparation of m-Trifluoromethoxyaniline
According to the procedure of J. S. Buck et al, Org. Synth. II, 44 (1943), m-trifluoromethoxybenzamide (4 g, 19.5 mmol) was added portionwise to a cold, stirred mixture of 5% NaOCl (28.26 mL) and 50% NaOH (1.41 mL). The mixture was gently warmed until it became homogeneous (about 55° C.) and then kept at 70° C. (internal temperature) for 2 hours. At this point additional 50% NaOH was added (7.7 mL) and the mixture was heated at 80° C. for 3 hours. Upon cooling it was extracted with ether (3X); the extracts were washed with brine and dried (MgSO 4 ). The ether was distilled off at atmospheric pressure to avoid losses of the somewhat volatile amine. The residual brown oil, obtained in quantitative yield, was pure enough to be used as such in the next step. If needed, however, it can be further purified by distillation, b.p. 85°-86° C. at 20 mm Hg (W. A Sheppard, J. Org. Chem., 29, 1 (1964): 89° C./20mm or 70° C./7mm).
NMR (CDCl 3 , 400 MHz): δ 3.9 (broad s, NH 2 ), 6.51 (s, 1H, Ar-H), 6.58 (mm, 2H, Ar-H), 7.13 (t, 1H, J=8Hz, Ar-H)
Step 2) Preparation of m-Trifluoromethoxyphenylhydrazine Hydrochloride
According to the procedure of I. T. Barnish et al, J. Chem. Soc. Perkin I, 215 (1974), m-trifluoromethoxyaniline (54.71 mmol) was added to cold, concentrated HCl (142 mL) and the suspension diazotized at -2° C. (internal temperature) by adding a solution of NaNO 2 (4.15 g, 1.1 equivalents) in water (35.6 mL). After 15-30 minutes, the mixture was treated with a solution of urea (2.5 g) in water (8.5 mL). It was then cooled to -4° C. (internal temperature) and reduced by rapidly adding a solution of tin (II) chloride dihydrate (15.43 g, 1.25 equivalents) in concentrated HCl (49.3 mL) previously cooled to -50° C. The resulting off white solid was collected after 1 hour and dried to constant weight (6.83 g, 54.6%, m.p. sintering around 143° C.). It was of sufficient purity to be used as such in the next step.
Note. A slightly higher yield (65.3%) was obtained by by basifying the whole reaction mixture (to pH 13, with cold 50% NaOH) prior to the extraction of the hydrazine with ethyl acetate. The salt was then obtained by adding an excess of anhydrous HCl to an ethereal solution of the base.
NMR (DMSO-d 6 , 200 MHz): δ 6.86 (m, 3H, C 2 H+C 4 H+C 6 H), 7.4 (5, 1H, C 5 H)
Step 3) Preparation of 4-[3-Trifluoromethoxyphenylhydrazono]-1-butanol
m-Trifluoromethoxyphenylhydrazine hydrochloride (6.83 g, 29.9 mmol), was dissolved in THF (83 mL) and water (83 mL). Dihydrofuran (2.1 g, 2.39 mL, 29.9 mmol, d=0.927) was added in one portion and the reaction mixture was stirred under nitrogen for 3 hours. At this point no hydrazine was present by TLC. The mixture was extracted with ether (3X) and the extracts were washed with brine, dried (MgSO 4 ) and evaporated to dryness. The residue (yellow oil, 6.94 g, 94%, mixture of E/Z isomers) was used as such in the next step.
Step 4) Preparation of 4- and 6-Trifluoromethoxytryptophol
A mixture of crude 4-[3-trifluoromethoxyphenylhydrazono]-1-butanol (6 g, 22.9 mmol) and zinc choloride (7.35 g, 53.42 mmol) in ethylene glycol (38 mL) was heated under nitrogen until homogeneous (at 85°-90° C.). The temperature was raised to 150°-160° C. for 3 hours. At this point no starting material appeared to be present by TLC (methanol-chloroform 1:9 or CH 2 Cl 2 -EtOAc 95:5). The hydrazone stains blue with Vaughn's reagent vs. reddish-brown for the tryptophols). The cooled reaction mixture was poured into 1N-HCl (18 mL) and extracted with ether (4X). The extracts were washed with brine, dried (MgSO 4 ) and evaporated to dryness. Flash chromatography of the residue (on silica Merck-60, using either dichloromethane-EtOAc 95:5 or toluene-EtOAc 70:30 as eluant) afforded only partial separation of the 6- from the more polar 4-isomer (brown oil, 1.8 g, 32%). Therefore the mixture of 6- and 4-substituted tryptophols (ratio ca. 2.5:1) was used in the next step.
6-isomer
NMR (DMSO-d 6 , 400 MHz): δ 2.82 (t, 2H, J=7 Hz, ArCH 2 ), 3.62 (m, 2H, CH 2 OH), 4.61 (t, 1H, J=5.3 Hz, OH), 6.93 (d, J=8 Hz, 1H, Ar-H), 7.23 (s, 1H, Ar-H), 7.27 (s, 1H, Ar-H), 7.57 (d, 1H, Ar-H), 11.0 (broad s, 1H, NH).
MS (El, m/z): 245 (M) + , 214 (bp, M-CH 2 OH) + .
4-isomer
NMR (DMSO-d 6 , 400 MHz): δ 2.90 (t, 2H, J=7 Hz, ArCH 2 ), 3.63 (m, 2H, CH 2 OH), 4.59 (t, 1H, J=5.2 Hz, OH), 6.89 (d, J=7.7 Hz, 1H, Ar-H), 7.08 (t, 1H, J=8 Hz, Ar-H), 7.22 (s, 1H, Ar-H), 7.34 (d, 1H, J=8 Hz, Ar-H), 11.22 (broad s, 1H, NH).
Step 5) Preparation of 1-Ethyl-1,3,4,9-tetrahydro-7-(trifluoromethoxy)-pyrano-[3,4-b]indole-1-acetic Acid Methyl Ester and 1-Ethyl-1,3,4,9-tetrahydro-5-(trifluoromethoxy)pyrano-[3,4-b]indole-1-acetic Acid Methyl Ester.
A solution of a mixture of 4- and 6-trifluoromethoxytryptophol (1.8 g, 7.9 mmol), methyl 3-methoxy-2-pentenoate (1.7 g, 11.7 mmol) and a catalytic amount of BF 3 .Et 2 O (0.2 mL) in dichloromethane (35 mL) was stirred at room temperature under nitrogen for 2 hours. The solution was washed with 5% NaHCO 3 and brine and dried (MgSO 4 ). Removal of the solvent yielded an amber oil (3 g). Flash chromatography of the residue (silica Merck-60, light petroleum ether-ether 75:25) provided 1.19 g (42.5%) of the 7-trifluoromethoxy isomer together with 0.55 g (19.6%) of the more polar 5-isomer and 0.25 g of mixture. Total yield: 1.99 g (71%). The 7-trifluoromethoxy isomer was recrystallized from ether-light petroleum ether, m.p. 78°-82° C.
NMR (CDCl 3 , 400 MHz): δ 0.81 (t, 3H, J=7.3 Hz, CCH 2 CH 3 ), 1.97 and 2.12 (2 m, 2H, CCH 2 CH 3 ), 2.75 (m, 2H, ArCH 2 CH 2 O), 2.95 (dd, 2H, CCH 2 CO 2 ), 3.72 (s, 3H, CO 2 CH 3 ), 3.85 and 4.02 (2 m, 2H, CH 2 CH 2 O), 6.97 (d, J=7.5 Hz, 1H, Harom), 7.23 (s, 1H, Harom), 7.44 (d, 1H, J=8.5 Hz, Harom), 9.23 (s, 1H, NH).
MS (El, m/z): 357 (M) + , 328 (M-C 2 H 5 ) + , 284 (b.p.) + .
Anal. Calcd. for C 17 H 18 F 3 NO 4 : C, 57.14; H, 5.08; N, 3.92%. Found: C, 56.90; H, 5.37; N, 3.88%.
The 5-trifluoromethoxy isomer was recrystallized from ether-petroleum ether, m.p. 112°-113° C.
NMR (CDCl 3 , 400 MHz): δ 0.81 (t, 3H, J=7.3 Hz, CCH 2 CH 3 ), 1.95 and 2.11 (2m, 2H, CCH 2 CH 3 ), 2.94 (m, 2H, ArCH 2 CH 2 O), 2.96 (dd, 2H, CH 2 CO 2 ), 3.72 (s, 3H, CO 2 CH 3 ), 3.92 and 4.01 (2m, 2H, CCH 2 O), 6.92 (d, J=8 Hz, 1H, Harom), 7.08 (t, 1H, J=8 Hz, Harom), 7.26 (d, J=8 Hz, 1H, Harom), 9.25 (s, 1H, NH).
MS (El, m/z): 357 (M) + , 328 (M-C 2 H 5 ) + , 284 (b.p.) + .
Anal. Calcd. for C 17 H 18 F 3 NO 4 : C, 57.14; H, 5.08; N, 3.92%. Found: C, 57.44; H, 5.62; N, 4.00%.
Step 6) Preparation of 1-Ethyl-1,3,4,9-tetrahydro-7-(trifluoromethoxy)-pyrano-[3,4-b]indole-1-acetic Acid
A solution of 1-ethyl-1,3,4,9-tetrahydro-7-(trifluoromethoxy)pyrano-[3,4-b]indole-1-acetic acid methyl ester (3 g, 8.4 mmol) in ethanol (25 mL) was treated with 10% NaOH (24 mL) and stirred overnight under nitrogen at room temperature. The ethanol was removed in vacuo and the aqueous phase was diluted with water and acidified (to pH3) with cold, concentrated HCl. The mixture was extracted with ether and the extracts were combined, washed with brine and dried (MgSO 4 ). Removal of the solvent yielded the crude title compound as a yellow solid (2.8 g, 97%). It was recrystallized from ether-hexane to provide an off-white solid (1.75 g, 61%), m.p. 166°-168° C. (dec.).
IR (KBr, cm -1 ): 1720 (CO)
UV (MeOH, nm): 280.5 (ε7,650), 288.5 (ε7,100).
NMR (CDCl 3 , 400 MHz): δ 0.85 (t, 3H, J=7.3 Hz, CCH 2 CH 3 ), 2.02 and 2.10 (mm, 2H, CCH 2 , CH 3 ), 2.81 (m, 2H, ArCH 2 ), 3.01 (dd, 2H, CCH 2 CO 2 ), 4.05 (m, 2H, CH 2 OH), 6.98 (d, 1H, J=8.5 Hz, Harom), 7.2 (s, 1H, Harom), 7.44 (d, J=8.5 Hz, 1H, Harom), 8.82 (s, 1H, NH).
MS (EI, m/z): 343 (M) + , 314 (M-C 2 H 5 ) + , 284 (b.p.), 69 (CF 3 ) + .
Anal. Calcd. for C 16 H 16 F 3 NO 4 : C, 55.98; H, 4.70; N, 4.08% Found: C, 55.81; H, 4.87; N, 4.23%.
Step 7) Preparation of 1-Ethyl-1,3,4,9-tetrahydro-5-(trifluoromethoxy)-pyrano-[3,4-b]indole-1-acetic Acid
A solution of 1-ethyl-1,3,4,9-tetrahydro-5-(trifluoromethoxy)pyrano[3,4-b]indole-1-acetic acid methyl ester (1 g, 2.8 mmol) in ethanol (10 mL) was treated with 10% NaOH (10 mL) and stirred overnight under nitrogen at room temperature. The ethanol was removed in vacuo and the residue was diluted with water, acidified (to pH3) with cold concentrated HCl and extracted with ether. The extracts were washed with brine and dried (MgSO 4 ). Removal of the solvent yielded the crude title compound. It was recrystallized from ether-hexane to provide a white solid (0.7 g, 73%), m.p. 158°-159° C.
IR (KBr, cm -1 ): 1710 (CO).
UV (MeOH, nm): 277.5 (ε8,300).
NMR (CDCl 3 , 400 MHz): δ 0.87 (t, 3H, J=7.3 Hz, CCH 2 CH 3 ), 2.02 and 2.12 (mm, 2H, CCH 2 CH 3 ), 3.0 (m, 2H, ArCH 2 CH 2 O), 3.03 (dd, 2H, CH 2 CO 2 ), 4.06 (m, 2H, CCH 2 O), 6.94 (d, J=7 Hz, 1H, Harom), 7.09 (t, 1H, J=8 Hz, Harom), 7.22 (d, J=8.4 Hz, 1H, Harom), 8.9 (s, 1H, NH).
MS (EI, m/z): 343 (M) + , 314(M-C 2 H 5 ) + , 284(b.p.), 69(CF 3 ) + .
Anal. Calcd. for C 16 H 16 F 3 NO 4 : C, 55.98; H, 4.70; N, 4.08%. Found: C, 55.62; H, 4.85; N, 4.31%.
EXAMPLE 2
1-Ethyl-1,3,4,9-tetrahydro-7-(trifluoromethoxy)-pyrano-[3,4-b]indole-1-acetic Acid and 1-Ethyl-1,3,4,9-tetrahydro-5-(trifluoromethoxy)-pyrano-[3,4-b]indole-1-acetic Acid
Process B
Step 1) Preparation of 2-[3-Trifluoromethoxyphenylhydrazono]glutaric Acid Monoethyl Ester
m-Trifluoromethoxyaniline (1.77 g, 10 mmol prepared by the process of Example 1, Step 1) was added dropwise to a stirred and cooled (ice bath) mixture of concentrated HCl (2.46 mL, 29.61 mmol) and water (3.5 mL). The resulting suspension was cooled to -10° C. and treated dropwise with a solution of NaNO 2 (0.690 g, 10 mmol) in water (1.95 mL) taking care to keep the temperature below -5° C. When the diazotization was complete (10-15 minutes) the solution was cooled to -10° C. and added rapidly to a mechanically stirred, ice cold solution of KOH (2.23 g) in water (5.2 mL) to which have just been added ice (4.5 g) and diethyl -acetyl glutarate (2.3 g, 2.14 mL, 10 mmol, d=1.071). The deep yellow solution was stirred in an ice bath for 30 minutes, slightly acidified in the cold with 6N-HCl and extracted with ether. The extracts were washed (brine), dried (MgSO 4 ) and evaporated to yield a red oil that solidified upon standing. Flash chromatography of the residue (pre-adsorbed on silica Merck-60, dichloromethane-ethyl acetate 90:10 and 80:20) provided a small quantity of crude diester 2-[3-trifluoromethoxyphenylhydrazono]glutaric acid diethyl ester followed by the more polar monoacid title compound (1.13 g, 32.5%, red solid) as the major component.
NMR (CDCl 3 , 200 MHz): δ 1.4 (t, 3H, CH 2 CH 3 ), 2.75 (m, 2H, CCH 2 ), 2.90 (m, 2H, CH 2 C), 4.25 (q, 2H, CH 2 CH 3 ), 6.8 (d, 1H, Ar-H), 7.0 (d, 1H, Ar-H), 7.1 (s, 1H, Ar-H), 7.3 (m, 1H, Ar-H), 9.5 (s, 1H, NH).
MS (EI, m/z): 348 (M) + , 274 (M-EtOH-CO) + , 246, 176 (b.p., ##STR5##
Further washing of the column with methanol gave a small quantity of the corresponding diacid 2-[3-trifluoromethoxyphenylhydrozono]glutaric acid.
Step 2) Preparation of 2-[3-Trifluoromethoxyphenylhydrazono]glutaric Acid Diethyl Ester
A solution of 2-[3-trifluoromethoxyphenylhydrazono]glutaric acid mono ethyl ester (1.2 g, 3.17 mmol) in 15% ethanolic HCl (w/w, 8 mL) was gently refluxed for 4 hours. Anhydrous HCl was then bubbled through while heating (10 minutes) and the mixture was refluxed another 30 minutes. The solution was cooled, diluted with water and extracted with ether. The extracts were washed (brine and 5% NaHCO 3 ), dried (MgSO 4 ) and evaporated to dryness. Flash chromatography of the residue (on silica Merck-60, toluene-EtOAc 98:2 and 97:3) yielded the title hydrazone diesters (less polar isomer A, yellow solid, 0.661 g, 55.5%; more polar isomer B, pale yellow oil, 0.244 g, 20.5%).
Isomer A
NMR (CDCl 3 , 200 MHz): δ 1.30 (t, 3H, CH 2 CH 3 ), 1.39 (t, 3H, CH 2 CH 3 ), 2.68 (t, 2H, CH 2 C), 2.90 (t, 2H, CH 2 C), 4.16 (q, 2H, CH 2 CH 3 ), 4.3 (q, 2H, CH 2 CH 3 ), 6.8 (d, 1H, Ar-H), 7.0 (d, 1H, Ar-H), 7.05 (s, 1H, Ar-H), 7.28 (t, 1H, Ar-H).
MS (EI, m/z): 376 (M) + , 176 (b.p. ##STR6##
Isomer B
NMR (CDCl 3 , 200 MH): δ 1.25 (t, 3H, CH 2 CH 3 ), 1.4 (t, 3H, CH 2 CH 3 ), 2.7 (t, 2H, CH 2 C), 2.88 (t, 2H, CH 2 C), 4.18 (q, 2H, CH 2 CH 3 ), 4.32 (q, 2H, CH 2 CH 3 ), 6.82 (d, 1H, Ar-H), 7.14 (d, 1H, Ar-H), 7.15 (s, 1H, Ar-H), 7.30 (t, 1H, Ar-H).
MS (EI, m/z): 376 (M) + , 330 (M-CO) + , 302, 274, 200, 176 (b.p. ##STR7##
Further washing of the column gave a small quantity of the more polar mixture of 4- and 6-trifluoromethoxy-2-carboethoxy-3-indoleacetic acid ethyl ester.
Step 3) Preparation of 4- and 6-Trifluoromethoxy-2-carboethoxy-3-indoleacetic Acid Ethyl Ester
A solution of 2-[3-trifluoromethoxyphenylhydrazono]glutaric acid diethyl ester (isomer A, 0.608 g, 1.61 mmol) in glacial acetic acid (4 mL) containing BF 3 .etherate (0.24 mL) was stirred at reflux under nitrogen for 30 minutes. The solution was diluted with water and extracted with ether. The extracts were washed with 5% NaHCO 3 and brine, dried (MgSO 4 ) and evaporated to dryness. Flash chromatrography of the residue (on silica Merck-60, toluene-EtOAc 95:5) yielded the mixture of title compounds as a white solid (0.060 g, 10.4%), m.p. 110°-112° C.
NMR (CDCl 3 , 200 MHz): δ 1.25 (t, J=7 Hz, 3H, CH 3 ), 1.41 (t, J=7 Hz, 3H, CH 3 ), 4.14 (s, 2H, CH 2 CO 2 ), 4.16 (q, J=7 Hz, 2H, CH 2 ), 4.42 (q, J=7 Hz, 2H, CH 2 ), 7.04 (d, J=8 Hz, 1H, Ar-H), 7.26 (s, 1H, Ar-H), 7.65 (d, J=8.5 Hz, 1H, Ar-H), 9.0 (broad, 1H, NH).
MS (EI, m/z): 359 (M) + , 313, 286, 240 (b.p.).
Step 4) Preparation of 4- and 6-Trifluoromethoxy-2-carboxy-3-indoleacetic Acid
A solution of the mixture of 4- and 6-trifluoromethoxy-2-carboethoxy-3-indoleacetic acid ethyl ester (0.218 g, 0.6 mmol) in ethanol (2.5 mL) was treated with 2.5N-NaOH (1.39 mL, 3.47 mmol) and stirred at reflux under nitrogen for 30 minutes. The solvent was evaporated and the residue was diluted with water and extracted with ether. The aqueous layer was acidified in the cold with 2N-HCl (to pH 3) and extracted with ethyl acetate. The extracts were washed (brine) and dried (MgSO 4 ) to yield a mixture of 4- and 6-trifluoromethoxy-2-carboxy-3-indoleacetic acid as a yellow solid (0.152 g, 82.6%). This crude material (mixture of 4 and 6 isomers) was used as such in the next step.
Step 5) Preparation of 4- and 6-Trifluoromethoxy-2-carboxy-3-indoleacetic Acid Ethyl Ester
A solution of the crude mixture of 4- and 6-trifluoromethoxy-2-carboxy-3-indoleacetic acid (0.280 g, 0.59 mmol) in 0.5% ethanolic HCl (1.7 mL) was gently refluxed under nitrogen for 60 minutes. Removal of the solvent in vacuo yielded the crude mixture of 4- and 6-trifluoromethoxy-2-carboxy-3-indoleacetic acid ethyl ester as a yellow oil that solidified upon standing (0.170 g, 86.7%). This crude material (mixture of 4 and 6 isomers) was used as such in the next step.
Step 6) Preparation of 4- and 6-Trifluoromethoxy-3-indoleacetic Acid Ethyl Ester
A crude mixture of the 4- and 6-trifluoromethoxy-2-carboxy-3-indoleacetic acid ethyl ester (0.160 g, 0.48 mmole) in quinoline (3 mL) containing a catalytical amount of 39KAF [0.030 g, prepared according to Connor et al, J. Amer. Chem. Soc., 54, 1142 (1932)] was stirred under nitrogen at 200° C. (oil bath temperature) until the evolution of CO 2 ceased (about 20 minutes). Upon cooling the dark mixture was diluted with ether, filtered (glass wool) to remove the catalyst and extracted with 1N HCl to remove as much quinoline as possible. The organic layer was then washed with brine, 5% NaHCO 3 and again brine, dried (MgSO 4 ) and evaporated to dryness. Flash chromatography of the residue (on silica Merck-60, toluene-EtOAc 95:5) afforded only partial separation of the 6-from the more polar 4-isomer. Therefore the mixture of the 6- and 4-trifluoromethoxy-3-indoleacetic acid ethyl ester (ratio about 3:1) was used in the next step (0.097 g, 70%, oil).
Step 7) Preparation of 4- and 6-(Trifluoromethoxy)tryptophol
A solution of the mixture of 4- and 6-trifluoromethoxy-3-indoleacetic acid ethyl ester (0.090 g, 0.313 mmol) in dry THF (5 mL, ex-CaH 2 ) was treated with LAH (0.0238 g, 6.27 mmol) and then stirred under nitrogen at room temperature for 30 minutes.
The mixture was diluted with THF and treated sequentially with water (0.025 mL), 1N-NaOH (0.025 mL), water (0.075 mL) and Na 2 SO 4 (0.3 g).
Removal of the solvent yielded a residue (0.075 g) identical (in two different solvent systems) with the mixture of 4- and 6-trifluoromethoxy tryptophols obtained in Example 1, Step 4.
This mixture of 4- and 6-trifluoromethoxy tryptophols was treated as in Process A, Example 1, Step 5 to Step 7 to produce
1-ethyl-1,3,4,9-tetrahydro-7-(trifluoromethxy)pyrano[3,4-b]indole-1-acetic acid; and
1-ethyl-1,3,4,9-tetrahydro-5-(trifluoromethoxy)pyrano[3,4-b]indole-1-acetic acid.
EXAMPLE 3
1-Ethyl-1,3,4,9-tetrahydro-6-(trifluoromethoxy)-pyrano[3,4-b]indole-1-acetic Acid
Process A
Step 1) Preparation of 4-Trifluoromethoxyphenylhydrazine Hydrochloride
A suspension of p-trifluoromethoxyaniline (5.0 g, 28 mmol) in 33 mL of concentrated HCl was diazotized at 0°-10° C. with a solution of sodium nitrite (2.0 g, 29 mmol) in H 2 O (17 mL). After stirring for 15 minutes at -5° C., the turbid solution was made clear by the addition of a few drops of water. A solution of stannous chloride (12.6 g, 56 mmol) in concentrated HCl (11 mL) was added in one portion. The mixture was stirred for 3 hours (with the ice bath removed after 1 hour), basified with 50% NaOH and extracted with EtOAc (2X). The organic phase was washed with 1N NaOH and brine, dried (KOH pellets) and acidified with anhydrous HCl. The precipitate was filtered and dried to give the title product as the white solid hydrochloride salt [4.83 g, mp 231° C. (dec.)]. A second crop was obtained by concentration of the mother liquors (0.62 g). Combined yield 5.45 g (85%).
1 H NMR (DMSO-d 6 , 400 MHz): δ 7.04 (d, 2H, J=8.5 Hz, Ar-H), 7.29 (d, 2H, J=8.5 Hz, Ar-H), 8.52 (broad, 1H, NHNH 2 ), 10.32 (broad, 3H, NHNH 3 + )
Anal. Calcd. for C 7 H 7 F 3 N 2 O.HCl: C, 36.78; H, 3.53; N, 12.25. Found C, 36.72; H, 3.76; N, 12.02.
Step 2) Preparation of 4-(4-Trifluoromethoxyphenylhydrazono)-1-butanol
A solution of 4-trifluoromethoxyphenylhydrazine hydrochloride (5.4 g, 23.7 mmol), and 2,3-dihydrofuran (1.65 g, 23.7 mmol) in 75 mL of THF-H 2 O (1:1, v/v) was stirred at room temperature for 2 hours. The reaction mixture was then partitioned between Et 2 O and water. The organic phase was washed with brine and dried. Removal of the solvent afforded fairly pure product as a yellow oil (5.67 g, 92%, mixture of E/Z isomers).
1 H NMR (CDCl 3 , 400 MHz): δ 1.8 (m, 2H, CCH 2 C), 3.85 (m, 2H, CH 2 CH 2 O), 6.9-7.2 (m, 5H, Ar-H+CCH=N).
MS (EI, m/z): 262 (M) + , 176 ##STR8##
Step 3) Preparation of 5-Trifluoromethoxytryptophol
A mixture of 4-(4-trifluoromethoxyphenylhydrazono)-1-butanol (5.6 g, 21.4 mmol) and zinc chloride (5.8 g, 42.8 mmol) in ethylene glycol (25 mL) was heated under nitrogen at 160° C. for 3 hours. The cooled reaction mixture was partitioned between Et 2 O and H 2 O. The organic phase was washed with 1N HCl and brine and dried (Na 2 SO 4 ). Removal of the solvent under reduced pressure gave fairly pure crude product (4.7 g, 90%, brown oil). It was used in the next step without further purification.
1 H NMR (CDCl 3 , 400 MHz): δ1.65 (broad, 1H, OH), 3.01 (t, 2H, J=6 Hz, ArCH 2 C), 3.92 (t, 2H, J=6 Hz, CCH 2 O), 7.08 (dd, 1H, J=8.5 Hz, Ar-H), 7.17 (d, 1H, J=2 Hz, Ar-H), 7.34 (d, 1H, J=8.5 Hz, Ar-H), 7.46 (s, 1H, Ar-H), 8.15 (broad, 1H, NH).
MS (EI, m/z): 245 (M) + , 214 (b.p., M-CH 2 OH) + , 145 (214-CF 3 ) + .
Step 4) Preparation of 1-Ethyl-1,3,4,9-tetrahydro-6-(trifluoromethoxy)-pyrano[3,4-b]indole-1-acetic Acid Methyl Ester
A solution of 5-trifluoromethoxytryptophol (4.7 g, 19.1 mmol), methyl 3-methoxy-2-pentenoate (3.3 g, 23 mmol) and a catalytic amount of BF 3 .Et 2 O in dry methylene chloride (20 mL) was stirred overnight at ambient temperature. The reaction mixture was diluted with an equal portion of methylene chloride, washed with 5% NaHCO 3 (50 mL) and brine (50 mL) and dried (Na 2 SO 4 ). Removal of the solvent afforded 7.2 g of an orange oil. The crude product was purified by flash chromatography (silica Merck-60, chloroform-methanol 95:5) to give the title compound (6.25 g, 92%, amber oil).
1 H NMR (CDCl 3 , 400 MHz): δ 0.81 (t, 3H, J=7 Hz, CH 2 CH 3 ), 1.98 and 2.13 (2m, 2H, CCH 2 CH 3 ), 2.75 (m, 2H, Ar-CH 2 C), 2.95 (dd, 2H, CCH 2 COO), 3.72 (s, 3H, CO 2 CH 3 ), 3.83 and 4.05 (2m, 2H, CCH 2 O), 7.03 (d, 1H, Ar-H), 7.31 (d, 1H, J=8.7 Hz, Ar-H), 7.32 (s, 1H, Ar-H), 9.2 (s, 1H, NH).
MS (EI, m/z): 357 (M) + , 328 (M-C 2 H 5 ) + , 284 (b.p.).
Step 5) Preparation of 1-Ethyl-1,3,4,9-tetrahydro-6-(trifluoromethoxy)-pyrano[3,4-b]indole-1-acetic Acid
A mixture of 1-ethyl-1,3,4,9-tetrahydro-6-(trifluoromethoxy)pyrano[3,4-b]-indole-1-acetic acid methyl ester (6.2 g, 17.4 mmol) in ethanol (80 mL) and 2.5N NaOH (24 mL) was stirred at ambient temperature under nitrogen for 3 hours. The ethanol was removed in vacuo and the residue was diluted with H 2 O (70 mL) and washed with ether. The aqueous phase was acidified (to pH3) with 2N-HCl and extracted with Et 2 O. The extract was washed with brine and dried (Na 2 SO 4 ). Removal of the solvent afforded the crude product (5.2 g, amber oil). Crystallization from Et 2 O-hexane gave 3.43 g of the pure title compound (mp 148° C., white solid). A second crop was obtained from the mother liquor (0.54 g, mp 148° C., light brown solid). The combined yield was 67%.
1 H NMR (CDCl 3 , 400 MHz): δ 0.87 (t, 3H, J=7.4 Hz, CH 2 CH 3 ), 2.02 and 2.12 (2m, 2H, CCH 2 CH 3 ), 2.82 (m, 2H, ArCH 2 C), 3.03 (dd, 2H, CCH 2 CO 2 ), 4.06 (m, 2H, ArCH 2 CH 2 O), 7.04 (d, 1H, J=8.5 Hz, Ar-H), 7.29 (d, 1H, J=8.5 Hz, Ar-H), 7.34 (s, 1H, Ar-H), 8.7 (s, 1H, NH).
IR (KBr, cm -1 ): 1695 (CO).
MS (CI, m/z): 344 (M+H) + , 343 (M) + , 314 (M-C 2 H 5 ) + , 284 (M-CH 2 COOH) + .
Anal. Calcd. for C 16 H 16 F 3 NO 4 : C, 55.98; H, 4.70; N, 4.08. Found: C, 55.88; H, 4.98; N, 4.00.
EXAMPLE 4
1-Ethyl-1,3,4,9-tetrahydro-8-(trifluoromethoxy)-pyrano[3,4-b]indole-1-acetic Acid
Process A
Step 1) Preparation of 2-Trifluoromethoxyphenylhydrazine Hydrochloride
A solution of o-trifluoromethoxyaniline (1.77 g, 10 mmol) in cold, concentrated HCl (11.6 mL) was diazotized at -5° C. (internal temperature) with a solution of NaNO 2 (0.69 g, 10 mmol) in water (11 mL). After 15-20 minutes the mixture was treated portionwise with a cold (0° C.) solution of tin (II)chloride dihydrate (4.5 g, 20 mmol) in concentrated HCl (4 mL). Stirring was continued for another 3 hours with the ice bath warming to room temperature after one hour. The suspension was recooled, basified with 50% NaOH (to pH 14) and extracted with ether. The extracts were washed with 1N NaOH, water and brine, dried (MgSO 4 ) and acidified with an excess of ethereal HCl. Removal of the solvent in vacuo yielded the title compound as an off-white solid (2 g, 88%). It was used without further purification.
NMR (DMSO-d 6 , 400 MHz): δ 7.03 (m, 1H, ArH), 7.18 (d, J=7.5 Hz, 1H, ArH), 7.34 (m, 2H, ArH), 8.40 (s, 1H, NH).
MS (EI, m/z): 197 (M) + , 77 (b.p.).
Step 2) Preparation of 4-(2-Trifluoromethoxyphenylhydrazono)-1-butanol
A solution of o-trifluoromethoxyphenylhydrazine hydrochloride (2 g, 8.77 mmol), and 2,3-dihydrofuran (0.614 g, 0.660 mL, 8.77 mmol, d=0.927) in a 1:1 (v/v) mixture of THF and water (30 mL) was stirred at room temperature for 1.5 hours under nitrogen. No hydrazine was present at this point by TLC. The mixture was extracted with ether and the ether extracts were washed with brine, dried (MgSO 4 ) and evaporated to dryness. The residue (pale yellow oil, 2.2 g, 95.7%, mixture of E/Z isomers) was used as such in the next step.
MS (EI, m/z): 262 (b.p., M) + , 218 (M-CH 2 O) + , 176 (M-N═CHCH 2 CH 2 CH 2 OH) + .
Step 3) Preparation of 7-Trifluoromethoxytryptophol
A mixture of crude 4-(2-trifluoromethoxyphenylhydrazono)-1-butanol (2.2 g, 8.4 mmol) and zinc chloride (2.28 g, 16.8 mmol) in ethyleneglycol (10 mL) was heated under nitrogen at 90° C. until homogeneous. The temperature was then raised to 160° C. for 3 hours. The cooled reaction mixture was poured into 1N-HCl and extracted with ether. The extracts were washed with brine, dried (MgSO 4 ) and evaporated to dryness. Flash chromatography of the residue (on silica Merck-60, eluant: CHCl 3 --CH 3 OH 95:5) afforded 0.980 g (48%) of the desired product.
NMR (CDCl 3 , 400 MHz): δ 3.03 (t, J=6.3 Hz, 2H, ArCH 2 ), 3.91 (q, J=6.2 Hz, 2H, CH 2 OH), 7.1 (m, 3H, ArH), 7.57 (m, 1H, ArH), 8.27 (broad, 1H, NH).
MS (EI, m/z): 245 (M) + , 214 (M-CH 3 O) + , 194, 128 (b.p.).
Step 4) Preparation of 1-Ethyl-1,3,4,9-tetrahydro-8-(trifluoromethoxy)-pyrano[3,4-b]indole-1-acetic Acid Methyl Ester
A solution of 7-trifluoromethoxytryptophol (0.98 g, 4 mmol), methyl 3-methoxy-2-pentenoate (0.72 g, 4 mmol) and a catalytic amount of boron trifluoride etherate in dichloromethane (18 mL) was stirred at room temperature for 1.5 hours. The solution was diluted with dichloromethane and washed with 5% NaHCO 3 and brine. The extracts were dried (MgSO 4 ) and evaporated to dryness. Flash chromatography of the residue (silica Merck-60, CHCl 3 ) provided 1.06 g (75%) of the pure product as a light yellow oil.
NMR (CDCl 3 , 400 MHz): δ 0.82 (t, J=7.4 Hz, 3H, CCH 3 ), 2.00 and 2.16 (2m, 2H, CCH 2 C), 2.80 (m, 2H, ArCH 2 C), 2.96 (dd, J=16.57 Hz, 2H, CCH 2 COO), 3.72 (s, 3H, COOCH 3 ), 3.95 and 4.05 (2m, 2H, CCH 2 O), 7.06 (d, J=4.9 Hz, 2H, ArH), 7.42 (m, 1H, ArH), 9.28 (broad s, 1H, NH).
MS (EI, m/z): 357 (M) + , 328 (M-C 2 H 5 ) + , 284 (b.p.).
Step 5) Preparation of 1-Ethyl-1,3,4,9-tetrahydro-8-(trifluoromethoxy)-pyrano[3,4-b]indole-1-acetic Acid
A solution of 1-ethyl-1,3,4,9-tetrahydro-8-(trifluoromethoxy)-pyrano[3,4-b]indole-1-acetic acid methyl ester (1.5 g, 4.2 mmol) in ethanol (20 mL) containing 2.5N NaOH (6 mL) was stirred for 3 hours at room temperature (reaction followed by TLC). The ethanol was removed in vacuo and the residue was diluted with water and washed with ether. The aqueous phase was acidified (to pH3) with cold, concentrated HCl and extracted with ether. The extracts were washed with brine, dried (MgSO 4 ) and evaporated to dryness. The crude product (1.4 g) was recrystallized from ether-hexane to provide a white solid (0.975 g, 68%, mp 142°-143.5° C.).
UV (MeOH, nm): λ278.5 (ε8,100), 227 (ε7,800).
NMR (CDCl 3 , 400 MHz): δ 0.86 (t, J=7.4 Hz, 3H, CCH 3 ), 2.05 and 2.15 (2m, 2H, CCH 2 C), 2.83 (m, 2H, ArCH 2 ), 3.05 (dd, J=16.5 Hz, 2H, CCH 2 COO), 4.08 (m, 2H, CCH 2 O), 7.07 (d, 2H, ArH), 7.42 (m, 1H, ArH), 8.94 (s, 1H, NH).
MS (EI, m/z): 343 (M) + , 314 (M-C 2 H 5 ) + , 284 (b.p.).
Anal. Calcd. for C 16 H 16 F 3 NO 4 : C, 55.98; H, 4.70; N, 4.08. Found: C, 55.84; H, 4.85; N, 4.02.
EXAMPLE 5
1-Ethyl-1,3,4,9-tetrahydro-7-(trifluoromethoxy)pyrano-[3,4-b]indole-1-acetic Acid 3-Oxo-1-isobenzofuranyl Ester
Step 1) Preparation of 3-Bromophthalide
A mixture of phthalide (7.5 g, 56 mmol) and N-bromosuccinimide (10 g, 55.5 mmol) in CCl 4 (150 mL) was heated at reflux for 3 hours (reaction checked by TLC). The mixture was filtered hot and the filtrate was evaporated to dryness to yield the crude title compound (11.15 g, 97%). It was used as such in the next step.
Step 2) Preparation of 1-Ethyl-1,3,4,9-tetrahydro-7-(trifluoromethoxy)-pyrano[3,4-b]indole-1-acetic Acid 3-Oxo-1-isobenzofuranyl Ester
A solution of 1-ethyl-1,3,4,9-tetrahydro-7-(trifluoromethoxy)pyrano[3,4-b]-indole-1-acetic acid (0.650 g, 1.89 mmol, prepared according to the procedure of Example 1), 3-bromophthalid (0.402 g, 1.89 mmol) and TEA (0.382 g, 3.79 mmol) in dry THF (60 mL) was refluxed for 4 hours. The solvent was evaporated and the residue was partitioned between water and ether. The extracts were washed with 5% NaHCO 3 and brine, dried (MgSO 4 ) and evaporated to dryness. Flash chromatography of the residue (on silica Merck-60, eluant: CHCl 3 ) provided 0.670 g (74.6%) of the pure product (as a mixture of diasteromers) which was recrystallized from ether-hexane, m.p. 150° C. (softening starts at 124° C.).
NMR (CDCl 3 , 400 MHz): δ 0.83 and 0.85 (2 overlapping triplets, J=7.3 Hz, 3H, CCH 3 ), 2.02 and 2.13 (2m, 2H, CCH 2 C), 2.82 (m, 2H, ArCH 2 ), 3.04 (dd, J=16.3 Hz, 2H, CCH 2 COO), 3.93 and 4.02 (2m, 2H, CCH 2 O), 6.99 (d, J=8.5 Hz, 1H, ArH), 7.22 (m, 1H, ArH), 7.42 (m, 3H, ArH), 7.65 (m, 2H, ArH), 7.89 (m, 1H, ArH), 8.68 and 8.83 (2s, NH).
MS (EI, m/z): 475 (M) + , 446 (M-C 2 H 5 ) + , 284, 133 (b.p.).
Anal. Calcd. for C 24 H 20 F 3 NO 6 : C, 60.63; H, 4.20; N, 2.94. Found: C, 60.40; H, 4.33; N, 3.26.
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Indole derivatives characterized by having a 1,3,4,9-tetrahydropyrano[3,4-b]indole-1-acetic acid nucleus bearing a trifluoromethoxy substituent in the 5-, 6-, 7-, or 8-position, and methods for their preparation and use, are disclosed. The derivatives are useful anti-inflammatory and analgesic agents.
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This application is a continuation of U.S. patent application Ser. No. 08/050,447, filed Jun. 25, 1993, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device for processing and interpreting drilling data, which is placed at the bottom of a well and, more particularly, to such a device intended to be used in oil drilling.
The present invention also relates to a method enabling this device to be implemented.
2. Description of Related Art
During the drilling of a well, for example an oil well, it is desirable for the foreman driller to ascertain the behaviour of the assembly and of the tool at the bottom of the well so as to monitor the drilling parameters better. It is preferable to ascertain these conditions in real time, this necessitating means for transmitting data from the bottom of the well to the surface.
Ascertaining the downhole conditions makes it possible to drill more assuredly and to reduce the drilling costs. Moreover, the foreman driller will have the option of reacting quickly to any downhole event, for example, change of rock type, wear of the tool or mechanical instability.
Several means for transmitting data from the bottom to the surface have been proposed. Among these means is transmission by electrical conductor, or by electromagnetic waves. Data transmission by pressure waves in the drilling mud has also been proposed. In such a system, the pressure of the mud circulating around the drill string is modulated for example by way of a servo valve mounted in a sub-unit placed in the drill string adjacent to the tool.
The pressure waves propagate at around 1500 m/s; they undergo numerous reflections between bottom and surface.
In view of the deterioration in the limitations inherent in modulating the pressure of the mud, and the need to preserve the quality of the data, the data flow rate remains low.
Currently, the data transmission flow rate does not exceed a few bits per second.
In the future, whatever the improvements in the systems for transmitting data in the mud, the speed of transmitting data from the bottom to the surface will remain limited.
In order to alleviate this disadvantage, the data should be preprocessed at the bottom, thus very significantly reducing the volume of the signals to be transmitted to the surface.
Document GB-A-2,216.661 describes a device for measuring the vibrations of a drill string, placed at the bottom of the well, and which includes a processor intended to record the data provided by an accelerometer. The device detects the acceleration levels which exceed a predetermined value and these levels alone are signalled to the surface. Hence, in this device, data which depend on a single parameter are sent to the surface only when a predetermined threshold is crossed, and this without any analysis of physical behaviour having been undertaken.
SUMMARY OF THE INVENTION
The subject of the present invention is a device for processing drilling data, placed at the bottom of a well and which is capable of compiling, at the bottom, various diagnostics specific to the global or individual behaviours of the drilling tool, the drill string, the drilling mud, and/or the well itself, and of signalling these diagnostics to the surface via one of the customary means for transmitting data.
To do this, the invention provides a device for processing and interpreting drilling data, intended to be mounted at the lower end of a drill string placed in a drilling well, the drill string being equipped with a drilling tool, with a measuring unit and with means for transmitting data from the bottom to the surface, characterised in that the device is adapted to send to the surface only abridged messages after interpreting the measurements acquired by the measuring unit.
The subject of the present invention is also a method enabling the aforesaid processing device to be implemented.
The said method includes the following steps:
acquiring measurements dependent on the behaviour of the drilling tool, and generating signals representing these measurements,
preprocessing the signals,
applying malfunction algorithms to the signals,
applying observers to the signals, and
sending to the surface abridged messages indicative of the measurements acquired at the bottom.
The method according to the invention makes it possible to optimize the processing of the data and to extract indications which, once transmitted to the surface, enable the drilling conditions to be improved.
Other characteristics and advantages of the present invention will emerge more clearly on reading the description below, given as reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic sectional view of a drilling unit,
FIG. 2 represents diagrammatically a processing and interpreting circuit, according to the invention, and
FIGS. 3 to 7 are, in each case, charts enabling the method according to the invention to be implemented.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 is represented a drilling unit comprising a mast 10 equipped, in a manner known per se, with a hook 12 from which is suspended a drill string represented generally by 14. The drill string 14 comprises a drilling tool 16, drill collars 18 and drill pipes 20. In the example illustrated, the drill string 14 is rotated by a rotary table 22 or by a motorized swivel. A duct 24 introduces pressurized drilling mud into the pipes 20. This mud leaves the tool and circulates in the space between the wall of the well and the drill string 14. It is recovered at the site of a duct 26, recycled and then directed to storage tanks (not shown).
According to the invention, a device 28 for processing and interpreting drilling data is placed inside the assembly, as close as desired to the tool, between the drill collars 18 and the tool 16. As will be described in further detail later, the device comprises a processing and interpreting circuit 30 and means for transmitting data to the surface. The means for transmitting data may comprise an electrical cable, a system of cabled pipes, an electromagnetic transmitter or, in the example illustrated, a system of transmission by pulses generated in the mud.
In this means of transmission, a servo valve mounted in a sub-unit 30 placed adjacent to the tool 16 is intended to modulate the flow of the pressurized mud selectively so as to create pressure waves in the mud. Devices for measuring and monitoring are placed in the sub-unit 30 making it possible, in a known manner, to generate pressure waves in the mud which are representative of the messages transmitted from the bottom. These pressure waves are detected at the surface by a pressure sensor 32, mounted on the duct 24.
The device 28 for processing and interpreting drilling data, as well as the method enabling it to be implemented make it possible to process the various measurements acquired at the bottom and to send various diagnostics to the surface, for example diagnostics regarding malfunctioning of the drilling unit (precession, bouncing of the tool, torsional waves or jamming) and regarding the condition of the tool (wear of the teeth and bearings of the three-cone bits, wear to the cutting tools).
In addition to these diagnostics the method of processing according to the invention makes it possible to quantize the various dynamic measurements making it possible to scale the severity of the vibrations, and thus making it possible to assess the effectiveness of the actions undertaken at the surface by the foreman driller.
As is represented in FIG. 2, the processing and interpreting circuit 30 receives data acquired by various measuring devices which are placed in a measuring unit 36 (see FIG. 1) situated next to the tool 16. Data coming from various strain gauges for tension 38, torsion 40 or bending 42, from various magnetometers 46, from axial 48, radial 50 and transverse 51 accelerometers meet up in a multiplexer 54, via anti-aliasing filters 52.
After analog/digital conversion 56, the signals are processed by as many processors 58 and signal processors 57 as necessary. An auxiliary input 60 makes it possible to fully parameterize the device at the surface (or at the bottom in the case of two-way transmission). The circuit processing and interpreting 34 is powered by a sub-unit 62 which includes an alternator 64 driven by the drilling mud at the site of an input 66, an electrical regulating circuit 68 and accumulators 70. A control bus 74 supervises, among other things, the transmission system 76 connected to a modulating servovalve 72.
A non-volatile memory 59 is intended to store information temporarily; this information is retained for interpretation on returning the tool to the surface.
Other measuring devices may be used to allow determination of the following parameters: weight on the tool, torque, internal and external pressures, internal and external temperatures and mud flow rate.
With the bottom measurements from the measuring unit 36, the processing circuit 34 makes it possible to signal to the surface various conditions, malfunctions or faults or severity of vibration of the drilling unit.
A method implementing the device of the present invention is represented diagrammatically in FIG. 3.
The signals from the various strain gauges 38 to 51 making up the measuring unit 36 are preprocessed, where appropriate, at 80 so as to remove the offsets, physically rescale the measurements and reposition them within a fixed reference. This preprocessing is represented in further detail-in FIG. 4. The meaning of the initials representing the signals is given below: DBNX: Bending moment at the bottom, about the X axis DBNY: Bending moment at the bottom, about the Y axis DMGX: Magnetometric measurements along the X axis DMGY: Magnetometric measurements along the Y axis DWOB: Weight on the tool DACZ: Acceleration along the Z axis DTOB: Torque on the tool
This preprocessing step makes it possible to check whether the set of measurements is correct and also enables the speed of rotation of the tool to be calculated from magnetometric measurements DMGX and DMGY. Since the measurements are made in a moving reference, they should be repositioned within the fixed reference.
Next, as represented in FIG. 3, the signals arising directly from the sensors 36, as well as the preprocessed signals, go through malfunction algorithms 82 and observers 84.
The malfunction algorithms 82 are represented in further detail in FIGS. 5 and 6. These algorithms enable the entropy of the various dynamic measurements (DWOB; DTOB; DBNX; DBNY) to be quantized.
From these measurements, it is possible to detect the following conditions of the drilling assembly:
level of rebound of the tool,
presence and characterization of rotational instabilities,
presence and characterization of chaotic lateral vibrations,
wear of the tool (bearings, teeth, etc.),
nozzle loss in the tool,
leaks in the region of the downhole motor,
sub-shock function rating,
jamming at the tool,
jamming or sticking at the stabilizers.
The step of the method represented in FIG. 6 makes it possible to detect all types of precession and to quantize them as a function of their direction.
In FIG. 7 is represented the final step of the processing of the data, that of the observers 84. This step enables the energy consumed by the tool per unit destroyed rock to be determined. With these data, it is possible to prepare an energy budget for the tool which constitutes, for the driller, a good indicator of the operation of the tool and of its advance.
With the development in the degree of understanding of downhole mechanical phenomena, the device will take into account new diagnostic capabilities.
The pressure sensor 32, intended to detect the pulses generated in the mud, is connected to a frame decoder and to an interpretation station (which are not shown) advantageously embodied by an office computer.
Thus, according to the invention, the processing circuit 30, instead of sending voluminous data to the surface, dependent on each of the measurements acquired at the bottom, sends to the surface only signals which indicate the condition of operation of the drilling unit. Quite obviously, the flow rate required for these transmissions remains compatible with the state of the art.
Even after compiling abridged messages, the flow rate may turn out to be still too low. The processing and interpreting device is capable of prioritizing the sending of these messages.
In order to ensure a wider field of investigation, the device for processing and interpreting drilling data of the invention can be used in combination with a device for dynamic measurements of a drill string, such as described in the document EP-A-0,431,136, or in French Patent Applications 90 09638 or 90 12978.
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A device for processing and interpreting drilling data is mounted at the lower end of a drill-pipe string located in a drilling well and provided with a drill bit and, measuring assembly. The device is arranged to transmit data from the bottom to the surface, but transmits only abbreviated messages to the surface after interpreting the measurements made by the measuring assembly. A method for implementing the device while transmitting data from the bottom of a drilling well to the surface in the form of abbreviated messages after interpreting the measurements made by the measuring assembly.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims priority from Japanese Patent Application No. JP-2009-084600 filed on Mar. 31, 2009 and the subject matter of which is incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to an illumination device that scans a draft by irradiating the draft with light and senses resultant reflected light by means of an optical sensor.
DESCRIPTION OF THE RELATED ART
In an image reading apparatus, a surface of a draft is illuminated with light by means of; for instance, a scanner. A photoelectric conversion element, such as a CCD and a CIS, receives resultant reflected light by way of a plurality of reduction optical systems or a fiber lens array capable of producing an equi-size upright image. A hitherto-known illumination system for a light source of an illumination device employed in the image reading apparatus is to illuminate a draft by means of a plurality of LEDs, a cold cathode fluorescent lamp (CCFL), or a xenon lamp.
When an illumination device, such as that mentioned above, reads the surface of a large A0-size draft, the image reading apparatus moves over the draft while illuminating the draft by means of the light source of the illumination device, thereby reading an image on the draft. To this end, some light sources use an optical guide having a plurality of light reflectance/reflection surfaces made in a transparent resin so as to illuminate an entire breadthwise area of the draft with light from LED light sources disposed outside the breadth of an image to be read.
For instance, (JP-A-2008-140726) describes an optical guide having LEDs serving as light sources that are mounted at respective end faces of the optical guide. Light led to inside of the optical guide propagates throughout a read area while undergoing total reflection within the optical guide. Minute rugged light refraction/reflection surfaces are made on one longitudinal side face of the optical guide in a direction orthogonal to the direction of a light exit.
In the illumination device having such a structure, light originated from the light source is led to inside of the optical guide, undergoes reflection on the minute rugged light refraction/reflection surfaces, and finally exits toward the draft. The light is expected to be uniform over the breadth of the document surface and in large quantity. Light is additionally expected to exhibit uniform luminous intensity despite fluctuations in a distance between the draft surface and the light source.
However, the related-art illumination device has been insufficient in terms of consistency in both light quantity and luminous intensity achieved in an axial direction.
SUMMARY
The exemplary embodiment of the present invention provides a technique for letting a light source making up an illumination device generate a uniform quantity of light over a breadth read range, as well as providing an illumination device that holds down fluctuations in illuminance stemming from variations in focal depth with respect to a surface of a draft.
An exemplary embodiment of the present invention provides an illumination device as illumination means of a scanner for illuminating a draft. The illumination device comprising: an optical guide for receiving light emitted from a light source and guiding the light by repetitive transmission and reflection; a reflective member for reflecting light transmitting in the optical guide to an outside of the optical guide within the optical guide; a supplemental reflective member for reflecting light leaked from the optical guide to an inside of the optical guide.
The configuration makes it possible to reflect the light leaked outside the light refraction/reflection surfaces of the optical guide toward the draft by means of a reflection member, to thus increase the quantity of outgoing light from the optical guide. Further, the reflection member is built in an area beneath the light refraction/reflection surfaces where small illuminance is achieved on a draft. Therefore, it is possible to make illuminance on a draft achieved over the entire breadth of an image uniform and further possible to make the density of a read image uniform.
Another exemplary embodiment of the present invention also provides an illumination device in which the light source element is disposed at each of both end faces of the plurality of coupled optical guides in their longitudinal directions and in which the reflection members are arranged in a symmetrical layout along the longitudinal direction of the optical guides and in correspondence with the plurality of respective optical guides.
When a draft having a large breadth is illuminated, the configuration makes it possible to make illuminance achieved on a draft uniform and symmetrical with respect to the breadth of the draft.
Another exemplary embodiment of the present invention also provides an illumination device in which the reflection member is provided in numbers along the axial direction of the optical guide and symmetrically with respect to the light refraction/reflection surfaces.
The configuration makes changes in illuminance achieved on a draft small even when a distance between the draft surface and the illumination device has changed and makes it possible to render illuminance achieved on a draft area uniform.
Another exemplary embodiment of the present invention provides an illumination device in which the reflection member has a cross-sectional area that is not uniform in the longitudinal direction of the optical guide.
The configuration makes it possible to lessen sharp variations in illuminance achieved at an end of the reflection member attributable to presence or absence of the reflection member, thereby rendering illuminance achieved on a draft surface uniform.
Another exemplary embodiment of the present invention provides an illumination device in which the reflection member is disposed in close proximity to the light refraction/reflection surface of the optical guide and also held by the optical guide.
The configuration makes it possible to efficiently illuminate the draft surface with the light exited to a reflection member side.
Another exemplary embodiment of the present invention provides an illumination device in which the reflection member is provided in numbers of rows in correspondence with the plurality of rows of light refraction/reflection surfaces of the optical guide.
The configuration makes it possible to efficiently illuminate a draft surface with the light exited to the reflection member side as well as to make illuminance achieved on a draft surface uniform.
Another exemplary embodiment of the present invention provides an illumination device in which a ring-shaped light shielding member is inserted to a light source element side of the optical guide.
The configuration makes it possible to block light exiting toward the draft, among light entering the optical guide from the light source element, immediately after entry into the optical guide, thereby lessening sharp variations in illuminance arising in the vicinity of a light entrance and making illuminance achieved on a draft surface uniform.
Another exemplary embodiment of the present invention provides an illumination device in which the light source element is an LED.
The configuration makes it possible to miniaturize a scanner.
Another exemplary embodiment of the present invention provides an illumination device that is illumination means of a scanner for illuminating a draft. A light source for illuminating the draft produces a main beam that exits in a direction orthogonal to a light refraction/reflection surface of an optical guide for guiding the light from a light source element in a breadthwise of the daft and a sub-beam that is reflected toward the document by a reflection member disposed parallel to the optical guide.
The configuration makes it possible to increase illuminance achieved on a draft surface and further lessen variations in light quantity even when variations arise in the position of the draft surface.
Another exemplary embodiment of the present invention provides an illumination device in which a focal point of the sub-beam is displaced from the position of a focal point of the main beam.
The configuration makes it possible to increase illuminance achieved on a draft surface and further lessen variations in light quantity even when variations arise in the position of the draft surface.
Another exemplary embodiment of the present invention provides an illumination device in which the reflection members are disposed symmetrically with respect to the light refraction/reflection surface of the optical guide.
The configuration makes it possible to easily increase illuminance on the draft surface.
Another exemplary embodiment of the present invention provides an illumination device in which the reflection member is provided in numbers in an axial direction of the optical guide.
The configuration makes it possible to increase illuminance achieved on a draft surface and make illuminance achieved on a draft surface more uniform.
The illumination device using the light source of the exemplary embodiments of the present invention makes it possible to increase illuminance achieved on the draft surface and make illuminance achieved on the draft surface uniform.
Exemplary embodiments of the present invention make it possible to illuminate a draft surface with direct light originating from a light source element by way of an optical guide and with reflected light, wherein the reflected light is generated by reflecting light, which has exited outside the optical guide, toward the draft surface by means of a reflection member disposed in a lower part of a light refraction/reflection surface formed on the optical guide. Further, the exemplary embodiments of the present invention make it possible to form the reflection member at a local area, where illuminance is low, on the optical guide along its breadthwise direction or a location where illuminance is desired to be arbitrarily increased. Accordingly, it is possible to realize an illumination device that increases illuminance on a draft surface, thereby exhibiting an illuminance distribution having partial inconsistency in intensity within the breadth of the draft or an illuminance distribution that is uniform over the breadth of the draft. Thus, a scanner exhibiting high reading accuracy can be provided.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A to 1E are schematic views of an illumination device of an embodiment;
FIG. 2 is a detailed view of an optical guide employed in the illumination device of the embodiment;
FIG. 3 is a diagram showing an operating principle and characteristics of the illumination device of the embodiment;
FIGS. 4A to 4C are descriptive views of a reflecting member employed in the illumination device of the embodiment;
FIG. 5 is a descriptive view of the reflecting member employed in the illumination device of the embodiment;
FIG. 6 is a graph showing an illuminance distribution of the illumination device of the embodiment;
FIG. 7 is a graph showing an effect of a light shielding member employed in the illumination device of the embodiment;
FIGS. 8A to 8C are schematic views of the illumination device of the embodiment;
FIGS. 9A and 9B are descriptive views of the reflecting member employed in the illumination device of the embodiment;
FIG. 10 is a diagram showing the operating principle and the characteristics of the illumination device of the embodiment;
FIG. 11 is a graph showing an illuminance distribution of the illumination device of the embodiment;
FIG. 12 is a graph of illuminance distribution achieved when a lens of a reduction optical system, which is to be used in the illumination device of the embodiment, is employed; and
FIG. 13 is a descriptive view of a scanner using the illumination device of the embodiment.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
An embodiment of the present invention is hereinbelow described by reference to the drawings.
A brief overview of an illumination device is first described by reference to FIGS. 1A to 1E .
The First Exemplary Embodiment
A first exemplary embodiment of the illumination device of the present invention is hereunder described.
FIGS. 1A to 1E are schematic views of the illumination device of the embodiment of the present invention. FIG. 1A is a plan view of the illumination device; FIG. 1B is a side cross-sectional view of the same taken along line A-A′; FIG. 1C is a front cross-sectional view of the same taken along line B-B′; FIG. 1D is a detailed view of a connecting portion of the illumination device; and FIG. 1E is a detailed view of a connecting member of the illumination device. FIG. 2 is a detailed view of an optical guide employed in the illumination device of the embodiment of the present invention.
Reference numeral 1 shown in FIG. 1A designates an optical guide that is made of a translucent material; that receives light radiated from an LED light source 4 , which will be described later, and guides the received light through an interior of the optical guide; and that guides the light received from an LED light source 4 while letting the light repeatedly undergo reflection and transmission within the optical guide. When used in a scanner, or the like, each of the optical guides 1 assumes a rod shape in many cases. In addition to a columnar rod-shaped member having a consistent thickness, a conical, rod-shaped member whose cross section (a diameter of a circle) gradually becomes smaller with an increasing distance from one end to a center portion is also conceivable.
In relation to an example configuration of the optical guide 1 provided below, explanations are provided by reference to an example conical, rod-shaped member whose cross section gradually becomes smaller in thickness with an increasing distance from one end to a center portion.
Reference numeral 2 shown in FIG. 1B designates light refraction/reflection surfaces corresponding to reflection portions; namely, a plurality of sawtooth light refraction/reflection surfaces provided on one side face of each of the optical guides 1 along its longitudinal/axial direction. Light passing through the optical guides 1 (or a portion of the light) undergoes reflection on the reflection portions 2 , to thus radiate outside of the optical guide 1 ; namely, a draft, or the like, that is an object to be read. An enlarged view of some of the reflection sections is provided in a circle of broken line shown in FIG. 2 .
A plurality of sawtooth faces of the light refraction/reflection surfaces 2 are integrally formed on a bulging bottom of the optical guide 1 and from a transparent resin by means of injection molding.
In consideration of translucency, heat resistance, and fluidity of a resin achieved during injection molding, heat resistant acryl, polycarbonate, amorphous polyolefin, and the like, are suitable for a material of the translucent resin. The optical guides 1 are thus completed.
Reference numeral 10 shown in FIG. 1A designates a guide rib provided on both side surfaces of the respective optical guides 1 . Reference numeral 3 designates a circuit board; 4 designates an LED light source; and 5 designates a connecting portion. The connection portions 5 hold the circuit boards 3 on which the LED light sources 4 are respectively mounted and the optical guides 1 . Reference numeral 6 designates a light shielding member; 7 designates a reflection member; and 8 designates a connecting member. The connecting member 8 couples the two optical guides 1 to each other. Reference numeral 9 designates a frame.
The illumination device of the first embodiment configured as mentioned above is described in a more specific manner.
In each of the LED light sources 4 , light originating from a blue LED element mounted in the light source is reflected by a pigment-based fluorescent agent made around the LED element, to thus illuminate as white light in a pulsing manner in synchronism with operation of a scanner (not shown) that travels back and forth above the draft.
Although the LED light source 4 is disposed on either lateral side of each of the optical guides 1 , the LED light sources exhibiting the same luminous efficiency are used in combination in order to hold down a difference between the illuminance distribution achieved on a right side of the document surface and the illuminance distribution achieved on a left side of the document surface, which will be caused by variations in light quantity.
A round hole for holding the optical guide 1 is provided in the connecting portion 5 , and an angular hole for positioning the LED light source 4 is also provided on a side of the connection portion 5 that holds the circuit board 3 . The center of the round hole and the center of the angular hole are in agreement with each other. The center of illumination of each of the LED light source 4 becomes thereby coincident with an axis of the corresponding optical guide 1 , so that the light radiated from the LED light sources 4 are efficiently received by the optical guides 1 .
When the optical guides 1 are fitted to the connecting portions 5 , light entrances of the optical guides 1 are inserted into the round holes of the respective connecting portions 5 . The ring-shaped light shielding member 6 is previously inserted to and held on either side of each of the optical guides 1 .
The circuit board 3 on which there is mounted the LED light source 4 is positioned and held with reference to an outer shape of the LED light source 4 by means of the angular hole of the connecting portion 5 . The optical guide 1 is also held in such a way that a light entrance end face of each of the optical guides 1 comes close to light-emitting surfaces of the respective LED light sources 4 along the round hole of the connecting portion 5 .
The light shielding members 6 shown in FIG. 1B are at this time inserted into corresponding round holes of the respective connecting portions 5 simultaneously with the optical guides 1 being fitted to the connecting portions 5 , whereupon clearance between the optical guides 1 and the corresponding connecting portions 5 is closed.
A material of the light shielding member 6 may also be produced in the form of an O-ring formed from; for instance, a sponge made by foaming white polyethylene, polyether, and the like, or rubber such as silicone.
Positioning grooves for positioning the direction of rotation of the frame 9 along with the guide ribs 10 formed on respective side surfaces of the optical guide 1 and guide grooves parallel to the light refraction/reflection surfaces 2 of the optical guides 1 are formed in the frame 9 shown in FIG. 1A by means of extrusion molding of aluminum. The surface of the frame 9 is subjected to treatment by means of anodized aluminum in order to absorb light leaked from the optical guides 1 .
Materials used as the reflection member 7 include a plastic film, such as a polyester film, whose surface is cladded with aluminum foil, which serves as a reflection layer, by means of an adhesive in consideration of translucency and a spectral characteristic; and metal, such as aluminum and chrome, which is formed by means of vacuum deposition, sputtering, and the like, and to which a thermoplastic film; for instance, PET, PBT, PEN, PMMA, polycarbonate, and the like, is thermally contact-bonded as a protective layer. Aluminum exhibiting a reflectance of 90% or more is used herein. The reflection member 7 corresponds to an auxiliary reflection portion.
The reflection member 7 is adhesively fastened to both ends of the frame 9 along the guide groove by means of a fastening member; for instance, an adhesive taper, or bonded to or formed integrally on exterior surfaces of the respective optical guides 1 .
The light radiated from the LED light sources 4 and entered the optical guides 1 travels while repeatedly undergoing reflection/transmission within the optical guides 1 , and a portion of the light is reflected by the light refraction/reflection surfaces 2 .
However, not all of the light reached the light refraction/reflection surfaces 2 is reflected, and a portion of the light leaks to the outside of the optical guide 1 as indicated by reference numeral b 5 . The thus-leaked light slips by the neighborhood of the light refraction/reflection surfaces 2 , to thus leak outside the optical guides 1 .
The thus-leaked light is again reflected by the reflection member 7 toward the inside of the optical guides 1 . The light is separated into light that exits from the inside of the optical guides 1 toward the surface of a draft, light that again repeatedly undergoes refraction or reflection within the optical guides 1 and is radiated to the surface of the draft, and light that is reflected by the reflection member 7 . The light repeatedly undergoes these operations.
In the optical guides 1 and the circuit boards 3 held by the connecting portions 5 , guide ribs 10 of the optical guides 1 are guided by positioning grooves of the frame 9 , and the connecting portions 5 are held by both end faces of the frame 9 .
As shown in FIG. 1E , the connecting member 8 is previously held at a leading end of one of the optical guides 1 inserted into the frame 9 from both ends thereof, and the two optical guides 1 are coupled together in a mutually-abutting manner at the center of the frame 9 .
Although the structure of the monochrome illumination device has been described thus far, the illumination device can also be embodied as an illumination device for reading a color image in which three colors; namely, R (red), G (green), and B (blue), of LED chips are integrated into a single package in the LED light source 4 and in which the G chip, which is the center element, is aligned with the axis of the optical guide.
An operating principle and characteristics of the thus-built illumination device of the first embodiment of the present invention are now described. FIG. 3 is a diagram showing an operating principle and characteristics of the illumination device of the embodiment of the present invention, in which the side cross-sectional view of the illumination device shown in FIG. 1A is illustrated. Arrow “b” depicts the manner of travel of light.
Of the light radiated from the LED light source 4 , a light component b 1 exiting at an angle of illumination to a direction of clearance between the optical guide 1 and the corresponding connecting portion 5 will exit directly to the outside from the clearance between the optical guide 1 and the corresponding connecting portion 5 as indicated by a broken arrow b 2 unless the light shielding member 6 is provided. As a result, illuminance of the draft surface achieved in the vicinity of the connecting portion 5 will become considerably high and eventually lead to an increase in variations in illuminance.
However, the light shielding member 6 is placed in the clearance between the optical guide 1 and the corresponding connecting portion 5 . Hence, light does not exit directly toward the draft after entering the optical guide 1 .
Of the other light components, a light component b 3 directly reached the light refraction/reflection surfaces 2 undergoes reflection on the light refraction/reflection surfaces 2 , to thus be radiated toward the surface of the draft. An entirety of a light component b 4 entered the optical guide 1 at a critical angle repeatedly undergoes total reflection on the side surface of the optical guide 1 , to thus eventually reach the light refraction/reflection surfaces 2 . The light component undergoes refraction or reflection on the light refraction/reflection surfaces, whereby the angle of the light component is sharply bent. Subsequently, the light exits upward from the other side surface opposing the light refraction/reflection surfaces 2 , thereby illuminating the surface of the draft.
However, not all of the light reached the light refraction/reflection surfaces 2 undergoes reflection. A portion of the light leaks out of the optical guide 1 as indicated by reference symbol b 5 . The thus-leaked light is again reflected toward the optical guide 1 by the reflection member 7 , to thus again repeatedly undergo refraction or reflection within the optical guide 1 along with the light exiting toward the draft surface from the inside of the optical guide 1 . Thus, light is separated into light that illuminates the draft surface and light that undergoes reflection on the reflecting member 7 . These operations are iterated.
Specifically, in an area where the reflection member 7 is provided, the reflection member 7 repeatedly lets the majority of the light leaked outside from the light refraction/reflection surfaces 2 exit toward the draft surface. Therefore, the efficiency of the light exited toward the draft surface is improved. The illuminance of the draft is consequently increased.
FIGS. 4A to 4C are descriptive views of a reflecting member employed in the illumination device of the embodiment of the present invention. The reflecting members 7 shown in FIG. 4A assume the shape of a rectangular parallelepiped. The reflecting members 7 shown in FIG. 4B assume the shape of a triangle. The reflecting members 7 shown in FIG. 4C assume the shape of a rhomboid.
In the case of the rectangular-parallelepiped shape shown in FIG. 4A , the reflecting members 7 are easy to machine. When the reflecting members 7 are affixed to the groove of the frame 9 , affixation can readily be practiced. In the case of the triangular shape shown in FIG. 4B , a cross-sectional area of each of the reflecting members 7 changes in its axial direction; hence, it is possible to gently change the quantity of reflected light. The rhombic shape shown in FIG. 4C yields the same advantage as that yielded by the triangular shape. In addition, an increase in illuminance of the center of the optical guide 1 can be implemented by means of only one reflecting member 7 .
FIG. 5 is a descriptive view of a reflecting member employed in the illumination device of the embodiment of the present invention. The plurality of reflecting members 7 are provided in correspondence with the plurality of light refraction/reflection surfaces 2 . In the embodiment shown in FIG. 5 , the light reflection/refraction surfaces 2 of the optical guide 1 are arranged in two parallel rows along a longitudinal direction of the optical guide 1 , and the reflecting members 7 are disposed on a lower portion of the optical guide 1 so as to correspond to the respective rows of the light refraction/reflection surfaces 2 .
In this case, since the area of the light refraction/reflection surfaces 2 can be increased, so that the illuminance of light exiting from the optical guide 1 toward the draft surface can further be increased. The distribution of illuminance of the draft surface can be increased by adjusting angles of the respective light refraction/reflection surfaces 2 . For instance, one reflection member 7 and another reflection member 7 are disposed in an asymmetrical layout with respect to an axis of the cross section of the optical guide 1 as shown in FIG. 5 , whereby the light reflected by the one reflection member 7 and the light reflected by the other reflection member 7 travel in respective different directions. The range of radiation on the draft surface can thereby be broadened. Even when a variation has arisen in a distance between the draft surface and the optical guide 1 , fluctuations in illuminance appearing on the draft surface can be lessened. Even when the reflection members 7 are arranged at angles with respect to the light refraction/reflection surfaces 2 , illuminance achieved on the draft surface can be adjusted.
An A0-size illumination device was built, and characteristics of the device were evaluated. FIG. 6 is a graph showing an illuminance distribution of the illumination device of the embodiment of the present invention. A distribution of illuminance of the A0-size illumination device is plotted.
A broken line shown in FIG. 6 depicts a characteristic achieved when there is not provided the reflection member 7 and when illuminance achieved at both ends of the illumination device is smaller than that achieved at the center of the illumination device. There is also a case where the illuminance achieved at both ends is larger than that achieved at the center. The reason for this is that a distribution of illuminance is greatly dependent on molding conditions used for molding the optical guide 1 . In some occasions, a sag arises in an edge as a result of the light refraction/reflection surfaces 2 not being perfectly transferred to a mold because of a variation in molding conditions. In other occasions, light transmittance is deteriorated as a result of the inside of the optical guide 1 becoming whitened dependent on a molding temperature used during molding operation.
For these reasons, it is first necessary to make the molding conditions stable in order to render the distribution of illuminance stable. Even if the molding conditions are made stable, variations of about 30%; however, still arises in illuminance when the breadth of the optical guide 1 is large. Moreover, when the illuminance of illumination is increased, variations in illuminance tend to become much greater.
However, in the present embodiment, the reflection member 7 is disposed at either end of the illumination device having a low degree of illuminance. Therefore, variations in illuminance of the illumination device fall within a range of about 15% as indicated by a solid line shown in FIG. 6 . Specifically, the reflection member 7 increased the quantity of light acquired at both ends of the illumination device by 15%. The shape of the reflection member assumes a rectangular parallelepiped in the present embodiment. If the shape is a triangle, fluctuations in illumination will become milder.
There can consequently be embodied a scanner that enables pursuit of uniform illuminance without deterioration of illuminance on a draft surface and that can prevent occurrence of unevenness in a read image, or the like.
FIG. 7 is a graph showing an effect of a light shielding member employed in the illumination device of the embodiment of the present invention. A broken line in the drawing depicts a distribution of illuminance achieved on a draft when the light shielding members 6 are not provided. As previously described by reference to FIG. 3 , or the like, the light component b 1 exited at an angle of illumination toward the clearance between the optical guide 1 and the connecting portion 5 , among the light radiated from the LED light source 4 , illuminates the draft surface as the light b 2 passed through the optical guide 1 .
In this case, the illuminance achieved at the light entrance of the optical guide 1 becomes excessively large, which in turn increases variations in luminance. On the contrary, a solid line depicts a distribution of illuminance achieved when the light shielding member 6 is placed in the clearance between the optical guide 1 and the connecting portion 5 . The light component b 1 exited toward the clearance between the optical guide 1 and the connecting portion 5 is blocked. Therefore, the light b 2 passed through the optical guide 1 does not arise, and variations in illuminance do not appear on the draft surface at the light entrance.
The LED light source 4 in which three colors, R (red), G (green), and B (blue), of LED chips are packed as a single package is illuminated in sequence of red, green, and blue, whereby a power-source-switchover illumination device for reading a color image can also be realized.
The Second Exemplary Embodiment
FIGS. 8A to 8C are schematic views of an illumination device of another exemplary embodiment of the present invention, showing a configuration of the illumination device of a second exemplary embodiment. FIG. 8A is a plan view of the illumination device; FIG. 8B is a lateral cross-sectional view of the same taken along line C-C′; and FIG. 8C is a front cross-sectional view of the same taken along line D-D′.
In FIG. 8A , reference numeral 21 designates an optical guide; 22 designates a light refraction/reflection surface that is provided on one longitudinal side surface of the optical guide 21 and that is made up of a plurality of sawtooth faces; 23 designates a circuit board; 24 designates an LED light source; and 25 designates a connecting portion that holds the circuit board 23 on which there is mounted the LED light source 24 and the optical guide 21 .
In FIG. 8B , reference numeral 26 designates a light shielding member; 27 designates a reflection member; 29 designates a frame; 28 designates another end; and 30 designates a light reflection layer formed on another end face.
FIGS. 9A and 9B are descriptive views of the reflecting member employed in the illumination device of the embodiment of the present invention. FIG. 9A is a view of attachment of the reflection member 27 , and FIG. 9B is a schematic illustration showing that the optical guide 21 holds the reflection member 27 . Reference numeral 31 designates a reflection surface; 32 designates a base member; 33 designates a support member; and 20 designates guide ribs provided on both sides of the optical guide 21 .
The optical guide 21 is built in such a way that a cross-sectional area (a diameter of a circle) of the optical guide becomes smaller from left to right as shown in FIGS. 8A to 8C .
The illumination device configured as mentioned above of the second embodiment is described in a more specific manner. First, light originating from a blue LED element mounted in the LED light source 24 is reflected by a pigment-based fluorescent agent made around the LED element, to thus illuminate as white light in a pulsing manner in synchronism with operation of a scanner (not shown) that travels back and forth above the draft. Although there is adopted a system in which the scanner travels from right to left, there may also be adopted a system in which a draft is moved over a stationary scanner.
A round hole for holding the optical guide 21 is provided in the connecting portion 25 , and an angular hole for positioning the LED light source 24 is also provided on a side of the connection portion 25 that holds the circuit board 23 . The center of the round hole and the center of the angular hole are in agreement with each other. The center of illumination of each of the LED light source 24 becomes thereby coincident with an axis of the optical guide 21 , so that the light radiated from the LED light sources 24 are efficiently received by the optical guide 21 .
As shown in FIG. 8B , the ring-shaped light shielding member 26 is previously inserted to and held on a light entrance of the optical guide 21 . When the optical guide 21 is attached to the connecting portion 25 , the light shielding member is inserted into the round hole of the connecting portion 25 . The circuit board 23 on which there is mounted the LED light source 24 is positioned and held with reference to an outer shape of the LED light source 24 by means of the angular hole of the connecting portion 25 . The optical guide 21 is also held in such a way that a light entrance end face of the optical guide 21 comes close to a light-emitting surface of the LED light source 24 along the round hole of the connecting portion 25 . The light shielding member 26 is at this time inserted into the round hole of the connecting portion 25 simultaneously with the optical guide 21 being fitted to the connecting portion 25 , whereupon clearance between the optical guide 21 and the connecting portion 25 is closed.
A material of the light shielding member 26 may also be produced in the form of an O-ring formed from; for instance, a sponge made by foaming white polyethylene, polyether, and the like, or rubber such as silicone.
Positioning grooves for positioning the direction of rotation of the frame 29 along with the guide ribs 20 formed on respective side surfaces of the optical guide 21 and guide grooves parallel to the light refraction/reflection surface 22 of the optical guide 21 are formed in the frame 29 by means of extrusion molding of aluminum. The surface of the frame 29 is subjected to treatment by means of anodized aluminum in order to absorb light leaked from the optical guide 21 .
Materials used as the reflection surface 31 shown in FIGS. 9A and 9B include a plastic film, such as a polyester film, whose surface is cladded with aluminum foil to serve as a reflection layer by means of an adhesive in consideration of translucency and a spectral characteristic; and metal, such as aluminum and chrome, which is formed as a protective layer by means of vacuum deposition, sputtering, and the like, and to which a thermoplastic film; for instance, PET, PBT, PEN, PMMA, polycarbonate, and the like, is thermally contact-bonded. Aluminum exhibiting a reflectance of 90% or more is used herein.
The reflection surface 31 is adhesively fastened to a black thin-plate-like base member 32 formed from a thermoplastic resin, such as ABS and PS, by means of a fastening member; for instance, an adhesive tape, or the like, thereby making up the reflection member 27 . Notches are further made in the base member 32 in agreement with pitches of the guide ribs 20 provided on both side surfaces of the optical guide 21 .
The thus-formed reflection member 27 is pushed from below such that the angular hole of the reflection member securing member 33 is inserted into the guide ribs 20 while the reflection surface 31 remains in contact with the light refraction/reflection surface 22 of the optical guide 21 and while the guide ribs 20 provided on both side surfaces of the optical guide 21 and the notches formed in the base member 32 are positionally aligned to each other. The reflection member 27 is thereby engaged with the optical guide 21 . The reflection member securing member 33 and the base member 32 are herein separated from each other but may also be formed integrally.
The guide ribs 20 of the optical guide 21 are guided by the positioning grooves of the frame 29 while the connecting portion 25 holds the optical guide 21 holding the reflection member 27 and the circuit board 24 , and the connecting portion 25 is held by an end face of the frame 29 .
The optical guide 21 and the light refraction/reflection surface 22 with a plurality of sawtooth faces provided on the optical guide are formed integrally from a transparent resin by means of injection molding. The plurality of sawtooth faces of the light refraction/reflection surface 22 are formed on a bulging bottom surface of the optical guide 21 .
In consideration of translucency, heat resistance, and fluidity of a resin achieved during injection molding, heat resistant acryl, polycarbonate, amorphous polyolefin, and the like, are suitable for a material of the transparent resin.
A light reflection layer 30 is also formed on the other end 28 of the optical guide 21 by means of evaporation or dipping of aluminum. The light reflection layer can also be made by affixing an aluminum tape to the other end, wherein the aluminum tape is made by bonding aluminum foil by means of a transparent adhesive. Alternatively, the light reflection layer can also be made by inserting a cap made of a white resin into the other end.
Although the structure of the monochrome illumination device has been described herein, the illumination device can also be embodied as an illumination device for reading a color image in which three colors; namely, R (red), G (green), and B (blue), of LED chips are integrated into a single package in the LED light source 24 and in which the G chip is aligned with the axis of the optical guide.
An operating principle and characteristics of the thus-built illumination device of the second embodiment of the present invention are now described by reference to FIG. 10 . FIG. 10 is a diagram showing an operating principle and characteristics of the illumination device of the embodiment of the present invention; namely, an enlarged illustration of the side cross-sectional view of the illumination device shown in FIG. 8B . Arrow “c” depicts the manner of travel of light.
Of the light radiated from the LED light source 24 , a light component c 1 exiting at an angle of illumination to a direction of clearance between the optical guide 21 and the connecting portion 25 will exit directly to the outside from the clearance between the optical guide 21 and the connecting portion 25 as indicated by a broken arrow c 2 unless the light shielding member 26 is provided. As a result, illuminance of the draft surface achieved in the vicinity of the connecting portion 25 will become considerably high and eventually lead to an increase in variations in illuminance.
However, the light shielding member 26 is placed in the clearance between the optical guide 21 and the connecting portion 25 . Hence, light does not exit directly toward the draft after entering the optical guide 21 .
Of the other light components, a light component c 3 directly reached the light refraction/reflection surface 22 undergoes reflection on the light refraction/reflection surface 22 , to thus be radiated toward the surface of the draft. An entirety of a light component c 4 entered the optical guide 21 at a critical angle repeatedly undergoes total reflection on the side surface of the optical guide 21 , to thus eventually reach the light refraction/reflection surface 22 . The light component undergoes refraction or reflection on the light refraction/reflection surfaces, whereby the angle of the light component is sharply bent. Subsequently, the light exits upward from the other side surface opposing the light refraction/reflection surface 22 , thereby illuminating the surface of the draft.
However, not all of the light reached the light refraction/reflection surface 22 undergoes reflection toward the interior of the optical guide 21 . A portion of the light leaks out of the optical guide 21 as indicated by reference symbol c 5 . The thus-leaked light is again reflected toward the optical guide 21 by the reflection member 27 , to thus again undergo refraction or reflection within the optical guide 21 along with the light exiting toward the draft surface from the inside of the optical guide 21 . Thus, light is separated into light that illuminates the draft surface and light that travels toward the reflecting member 27 , and also repeatedly undergoes reflection within the optical guide 21 .
Specifically, in the area where the reflection member 27 is provided, the majority of the light leaked out of the optical guide 21 from the light refraction/reflection surface 22 is reflected by the reflection member 27 , to thus exit toward the draft surface. Therefore, the efficiency of the light exited toward the draft surface is improved. The illuminance of the draft is consequently increased.
Moreover, the reflection member 27 is disposed in close proximity to the light refraction/reflection surface 22 of the optical guide 21 ; hence, the majority of the light leaked outside is efficiently reflected and recycled.
The advantage is made effective, so long as the reflection member 27 is provided with the triangular shape and the rhombic shape described in connection with the first embodiment.
Of the light components entered the optical guide 21 , the light component reached the other end 28 after having repeatedly undergone total reflection returns to the optical guide 21 as a light component C 6 that has again undergone total reflection on the light reflection layer 30 . Thus, the light component is recycled and utilized for illuminating the draft surface without few losses.
An A3-size illumination device was built on the basis of such an operating principle, and characteristics of the device were evaluated. FIG. 11 is a graph showing an illuminance distribution of the illumination device of the embodiment of the present invention. A distribution of illuminance of the A3-size illumination device is plotted. A broken line depicts a characteristic achieved when there is not provided the reflection member 27 and when illuminance achieved at both ends of the illumination device is higher than that achieved at the center of the illumination device. There is also a case where the illuminance achieved at both ends is smaller than that achieved at the center.
The reason for this is that a distribution of illuminance is greatly dependent on molding conditions used for molding the optical guide 21 . In some occasions, a sag arises in an edge as a result of the light refraction/reflection surface 22 not being perfectly transferred to a mold because of a variation in molding conditions. In other occasions, light transmittance is deteriorated as a result of the inside of the optical guide 21 becoming whitened dependent on a molding temperature used during molding operation.
For these reasons, it is first necessary to make the molding conditions stable in order to render the distribution of illuminance stable. Even if the molding conditions are made stable, variations of about 30%; however, still arises in illuminance when the breadth of the optical guide 21 is large. Moreover, when the illuminance of illumination is increased, variations in illuminance tend to become much greater.
For these reasons, the reflection member 27 is disposed at the center of the illumination device having a low degree of illuminance, to thus increase illuminance of the center, so that variations in illuminance of the illumination device fall within a range of about 10% as indicated by a solid line shown in FIG. 10 .
Specifically, by virtue of the reflection member 27 , the quantity of light acquired at the center of the illumination device is increased by 20%. The shape of the reflection member assumes a rectangular parallelepiped in the present embodiment. If the shape is a rhomboid, a superior effect for diminishing variations in illuminance will be yielded.
There can consequently be embodied a scanner that enables pursuit of uniform illuminance without deterioration of illuminance on a draft surface and that can prevent occurrence of unevenness in a read image, or the like.
FIG. 12 is a graph of illuminance distribution achieved when a lens of a reduction optical system, which is to be used in the illumination device of the embodiment of the present invention, is employed.
In the embodiment, the reflection member 27 is disposed at a position where to hold down variations in illuminance distribution on the assumption that a photoelectric conversion element is exposed to light after light reflected on the draft surface has passed through a lens that generates an upright image of equal size. When a lens of a reduction optical system is used, illuminance achieved at both ends of the optical guide must be made larger than that achieved at the center of the optical guide for reasons of a lens characteristic (a cosine fourth-power law) of the reduction optical system.
For this reason, illuminance achieved at both ends of the optical guide 21 must be increased. In this case, a desired distribution of illuminance, such as that indicated by a solid line shown in FIG. 12 , can be realized, so long as the reflection member 27 is disposed at either end of the optical guide 21 .
The LED light source 24 in which three colors, R (red), G (green), and B (blue), of LED chips are packed as a single package is illuminated in sequence of red, green, and blue, whereby a power-source-switchover illumination device for reading a color image can also be realized.
The Third Exemplary Embodiment
FIG. 13 is a descriptive view of a scanner using the illumination device of the embodiment of the present invention. A draft illumination section corresponds to the illumination device 40 described in connection with the second embodiment. Reference numeral 41 designates a fiber lens array serving as imaging means; and 42 designates a photoelectric conversion element for converting light into an electrical signal. The illumination device is, thus, primarily made up of the fiber lens array and the photoelectric conversion element.
Reference numeral 43 designates a reflection mirror disposed at either end of the illumination device, and the reflection mirrors correspond to the supplemental reflective members as in the case of the first exemplary embodiment. The reflection mirror 32 can also be provided in numbers for the optical guide 21 as shown in FIG. 13 . The reflection mirrors 43 can also be provided outside the optical guide 21 while respectively separated away from the optical guide 21 . As shown in FIG. 13 , the respective reflection mirrors 43 can be positioned in an asymmetrical layout with respect to an axis of the cross section of the optical guide 21 .
The fiber lens array 41 lets reflected light generated as a result of a draft 44 being illuminated by the illumination device 40 produce, in the form of light exhibiting an equi-size upright intensity distribution, an image on the photoelectric conversion element 42 serving as an image sensor. The photoelectric conversion element 42 produces an electrical output commensurate with the quantity of incident light.
An operating principle and characteristics of the thus-built scanner of the third embodiment are now described.
The LED light source 24 of the illumination device 40 illuminates the draft 44 in a pulsing manner in synchronism with operation of a scanner 50 that travels back and forth above the draft. The light radiated from the illumination device 40 according to inconsistencies in density of an image on the draft 44 is reflected from the draft surface as intensity distribution information. The reflected light enters the fiber lens array 41 , and an image is produced by the photoelectric conversion element 42 , whereupon image information is read.
Incidentally, illuminance achieved on the surface of the draft 44 greatly varies according to a distance between the illumination device and the surface of the draft 44 . For instance, when the distance between the draft surface and the illumination device 40 is changed by wrinkles in the draft 44 or a lift in the draft 44 , the distribution of illuminance of the draft 44 greatly changes in accordance with the distance.
Since the intensity of radiation is usually set so as to become maximum when no lift exists in the draft 44 , presence of a lift in the draft 44 induces variations in the distance between the illumination device 40 and the draft 44 , which in turn causes considerable variations in illuminance.
However, in the third embodiment, the reflection mirrors 43 are adhesively fixed to the frame 29 shown in FIG. 10 over a portion or entire breadth of the optical guide 21 by means of a double-faced tape, or the like. Light exiting from the optical guide 21 is thereby separated into light that forms an image on a draft surface e 1 ; light d 2 that undergoes reflection on one side of the reflection mirror 43 , to thus form an image at e 2 ; and light d 3 that undergoes reflection on the other side of the reflection mirror 43 , to thus form an image at e 3 .
Materials used for the reflection mirrors 43 include a plastic film, such as a polyester film, whose surface is cladded with aluminum foil as a reflection layer by means of an adhesive in consideration of translucency and a spectral characteristic; and metal, such as aluminum and chrome, which is formed by means of vacuum deposition, sputtering, and the like, and to which a thermoplastic film; for instance, PET, PBT, PEN, PMMA, polycarbonate, and the like, is thermally contact-bonded as a protective layer. Aluminum exhibiting a reflectance of 90% or more is used herein.
Even when a change in distance between the draft 44 and the illumination device 40 attributable to a lift in the draft 44 or an attachment error in the scanner 50 has arisen, the surface of the draft 44 can be illuminated with substantially the same illuminance as that achieved for reference, by means of the light reflected toward the draft 44 by means of the reflection mirrors 43 .
Specifically, it is possible to diminish unevenness in a read image attributable to variations in the position of the draft 44 and read an image with high quality.
Results yielded when the scanner 50 read the actual draft 44 are now mentioned. A reference distance between the illumination device 40 and the draft 44 was taken as 10 mm. When the draft 44 approached the illumination device 40 by 2 mm when compared with the reference distance, variations in light quantity was −15%. Conversely, when the draft 44 was separated from the illumination device by 2 mm when compared with the reference distance, variations in light quantity were −20%. In the case of the configuration described in connection with the third embodiment, variations in light quantity achieved when the draft 44 approached the illumination device 40 by 2 mm when compared with the reference distance were improved to −5%. Conversely, when the draft 44 was separated from the illumination device by 2 mm when compared with the reference distance, variations in light quantity were improved to −10%.
Even when wrinkles have arisen in the draft 44 , variations in illuminance achieved on an actual image of a draft surface can be held down, so that reading accuracy of an image is enhanced.
INDUSTRIAL APPLICABILITY
The exemplary embodiments of the present invention make it possible to realize an illumination device that exhibits high illumination efficiency on a draft surface and entails few variations in illuminance. The exemplary embodiments of the present invention also provide a highly reliable scanner whose illuminance is not affected by a distance to a draft surface.
In addition to being utilized for a scanner for reading information on a draft or another print medium and business machinery equipped with a scanner, the illumination device of the present invention can be utilized as a scanner incorporated in an electronic white board, or the like, that reads image information, or the like, on a sheet.
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An illumination device comprising: an optical guide for receiving light emitted from a light source and guiding the light by repetitive transmission and reflection; a reflective member for reflecting light transmitting in the optical guide to an outside of the optical guide within the optical guide; a supplemental reflective member for reflecting light transmitting the reflective member and light leaked from the optical guide while evading the optical guide to an inside of the optical guide, transmitting the reflective member and light leak.
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This is a division of application Ser. No. 337,803, filed Jan. 7, 1982, now U.S. Pat. No. 4,470,860.
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to the art of filament winding as applied to highly reinforced, hollow tubular members of large size and to fabricating such bodies to have thick walls that are densely packed with filamentary materials in substantially void free and uniformly dispersed thermoset resin. This invention, more particularly, relates to an improved filament winding procedure that efficiently produces these structures to dimensionally precise specifications.
2. Prior Art
Filament winding is well known for producing shaped bodies having continuous filamentary materials as reinforcements thereof. Measures ordinarily undertaken with this technique, however, would appear inadequate for efficiently fabricating hollow, highly reinforced, large tubular structures of the type contemplated by this invention.
The structures of this invention have thick and dimensionally precise walls densely packed with filamentary materials in substantially void free and uniformly dispersed thermoset resin. Usual filament winding practice, for a number of reasons, might suggest that these structures should be prepared in a series of repeated winding and cure operations in order to preserve dimensional precision in their walls.
Thick walls of large, highly reinforced, tubular structures are prone to slumping or other distortions during the winding and cure operations. This tendency is more pronounced in these highly reinforced, large, tubular structures that are fabricated with significant axial reinforcement. Filamentary materials that are positioned relatively highly axially (i.e., positioned with respect to the center longitudinal axis of the structure at an angle of between about ±5° and ±15°) to obtain this axial reinforcement cannot grasp preceding layers of fiber nearly as well as those that are positioned relatively more circumferentially. Large, highly reinforced tubular structures with such thick walls also take longer to fabricate. Slumping or other such distortions are generally time dependant; the longer time for fabrication, accordingly, provides for further aggravation thereof.
Still other considerations associated with the task of fabricating tubular structures of the aforementioned character include providing a relatively uniformly dispersed and substantially void free thermoset resin matrix for the densely packed filamentary materials. Certain resins, for example, may migrate in the thick walls prior to, and during curing, causing resin rich and resin poor areas in the structure. Moreover, a very large volume of filamentary materials is required to be wound within relatively short periods of time in producing large structures. Still further, large tubular structures of dimensional precision require mandrels with significant axial strength for dimensional stability.
OBJECTS OF THE INVENTION
It is an object of this invention to provide an improvement in filament winding for making highly reinforced, large tubular structures having thick walls densely packed with filamentary materials in substantially void free and uniformly dispersed thermoset resin.
It is an object of this invention to provide such an improvement in which there is greater efficiency in fabricating these structures than heretofore available in the prior art.
It is an object of this invention to provide such an improvement in which the thick walls of these tubular structures have exemplary dimensional precision.
These and other objects have been accomplished by filament winding practice in accordance with this invention as will be apparent from the following disclosure.
BRIEF DESCRIPTION OF THE INVENTION
This invention is directed to fabricating large, highly reinforced, hollow tubular structures. The tubular structures have thick, dimensionally precise walls with filamentary materials densely packed in thermoset resin. The thermoset resin is substantially void free and uniformly dispersed.
The fabrication comprises winding the filamentary materials about a hollow, thin walled aluminum mandrel having a central longitudinal axis. The mandrel is capable of radial expansion by application of elevated temperatures thereto. The winding is performed so as to form a plurality of alternate layers. The alternate layers comprise windings that, relative to the central longitudinal axis of the mandrel are (a) substantially circumferential windings of filamentary materials and (b) substantially axial windings of filamentary materials. The substantially circumferential windings are at a large angle relative to the longitudinal axis of the mandrel, e.g. between about ±80° to ±90°. The substantially axial windings are at a small angle to the longitudinal axis of the mandrel, e.g. between about ±5° and ±20°. Each of the alternate layers is in a matrix of thermosettable resin.
After completion of the winding of filamentary materials, the filament wound mandrel is heated to a temperature and for a time sufficient to cure the thermosettable resin. The heating raises the interior of the mandrel to a higher temperature than that of the exterior of the filament wound mandrel. The temperature difference between these interior and exterior locations is maintained preferably during substantially the entire heating step.
The resultant filament wound structure is then cooled at a rate such that stresses in the structure resulting from contraction during cooling are minimized; thereafter, the cooled structure is taken from the mandrel.
Aspects in preferred practice of the invention include (a) use of filamentary graphite materials for exceptional strength in reinforcement of the structures; (b) use of gelling epoxy resin compositions in radially outer portions of the alternate layers; and (c) circumferentially binding the substantially axial windings temporarily. Also, in present practice, radially inner portions of the alternate layers incorporate non-gelling epoxy resin compositions. In other more preferred practices, (d) the axial windings are grouped in pairs of plies in which the small angle of windings in a first ply is the negative of that of the second, and (e) each of the pair of plies is temporarily bound circumferentially with a highly tensioned belt or tape that is unbound therefrom as the subsequent substantially circumferential windings of filamentary materials progresses and forms the next layer and (f) the heating stage utilizes a shaft having banks of heaters radially disposed about the shaft within the mandrel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the mandrel of this invention partly broken away through its cylindrical section showing the interior thereof.
FIG. 2 is a section of the mandrel taken at 2--2 of FIG. 1.
FIG. 3 is a section of the mandrel taken at 3--3 of FIG. 1.
FIG. 4 is a partial side elevation of the mandrel, partly in section illustrating the interior thereof as in FIG. 1.
FIG. 5 illustrates diagrammatically a cross section of the wall of a tubular structure made in accordance with this invention.
DETAILED DESCRIPTION OF THE INVENTION
Tubular structures that are made in accordance with this invention include those between about 7 to 15 meters long, 1 to 3 meters in diameter and 2 to 6 centimeters in wall thickness and can be made even larger. The tubular structures have reinforcements by filamentary materials, such as carbon or graphite fibers, in a matrix of thermoset resin having a void content of about 6.5% by weight or less. These filaments are primarily positioned relatively axially and relatively circumferentially relative to a center longitudinal axis in each of the structures.
FIG. 1 depicts light weight, hollow mandrel 10 which can be made of aluminum and has been used in fabricating several of the structures of this invention. FIG. 1 is a side elevational view of mandrel 10, broken between its left and right ends 12,12' through its partially cutaway cylindrical center section 15. Left and right ends 12,12' have symmetry; they are hereinafter described together with right end elements denominated as the primes (') of those of the left.
Mandrel 10 is supported in a conventional filament winding apparatus. Arbors 14,14' of the filament winding apparatus are shown in FIG. 1 axially extending from the left and right ends 12,12' of mandrel 10, respectively.
Arbors 14, 14' bolt or otherwise are affixed to adapters 16,16', respectively, of mandrel 10. Adapters 16,16' bolt around their peripheries to respective left and right perforated disk end plates 18,18' which are perforated to receive chucking from the aforementioned filament winding apparatus. Perforated disk end plates 18,18' bolt, in turn, to left and right hubs 20,20' which are hollow.
Hubs 20,20' carry spokes 22A through 22L, 22A' through 22L'. Spokes 22A through 22G are shown in FIG. 1 and these as well as 22H through 22L, are shown in FIG. 3. Spokes 22A' through 22G' appear in FIG. 1 and 22G', 22H' and 22I' are seen in FIG. 4, 22J' through 22L' not shown in the drawings. Spokes 22A through 22L, 22A' through 22L', respectively, extend rigidly between the circumference of left and right hubs 20,20' to the periphery of left and right perforated plates 24,24'.
As shown in FIG. 2, annular rings 26,26' fixedly mount respectively around left and right hubs 20,20' and to left and right perforated plates 24,24'. Within respective left and right hubs 20,20' are welded ring flanges 28,28'. Ring flanges 28,28' are positioned within left and right hubs 20,20' under spokes 22A through 22L, 22A' through 22L'. Ring flanges 28,28' serve in mounting a hollow metal tube or shaft that extends axially through the interior of mandrel 10 during cure operations and carries radiant heater banks for temperature control during these operations, as fully discussed hereinafter.
Left and right perforated plates 24,24' carry left and right roll bars 30,30' and circular pin rings 32,32'. Roll bars 30,30' mount to perforated plates 24,24' through left and right brackets 34,34'. Pin rings 32,32' bolt about the outer periphery of plates 24,24'.
Pin rings 32,32' carry left and right pin distributions 36,36' fixedly about their peripheries. There are about 900 of these pins distributed in a circle around each pin ring 32,32'. Pin distributions 36,36' cooperate with their adjacent roll bars 30,30' and one another in connection with winding the relatively axially disposed filamentary materials about mandrel 10. During winding operations, the axial windings of filamentary materials are positioned along cylindrical section 15 by repeatedly looping tows of the filaments around ends 12,12' of mandrel 10. The ends of the loops are held by the pin ring distributions 36,36'. The tows of the axial windings are positioned at an angle of between about ±5° and ±25° relative to the center longitudinal axis of mandrel 10 and are layed adjacent one another.
Left and right end plates 24,24' also have holes 38,38'. Holes 38,38' serve to lighten mandrel 10 as well as provide for its ventilation during cure operations.
Cylindrical section 15 has thin wall 40 (between about 4 and 5 centimeters thick) with outer winding surface 42. Winding surface 42 is coated with teflon or the like release material.
Cylindrical section 15 is composed of a plurality of open ended, cylindrical sections that are fastened together at their ends, of which sections 44, 46, 47 and 48 are shown at least in part in FIG. 1. These cylindrical sections may be of any convenient axial dimension; most of the sections of mandrel 10 are about 3.2 meters long.
Cylindrical section 44 has flanges 50,52 which project inwardly from wall 40 circumferentially about respective left and right ends of cylindrical section 44. As seen better in FIG. 4, flange 50 is bolted to inwardly projecting flange 54 of cylindrical section 46. Although only bolt 56 is depicted in FIGS. 1 and 4, cylindrical sections 44 and 46 actually bolt about forty times or more to one another about flanges 50 and 54. Similarly, flange 52 of section 44 is bolted to the periphery of perforated end plate 24', one of which bolts is shown as 58. These bolts also fasten to pin ring 32' and end plate 24'.
Flanges 50, 54 form a circumferential rib for strengthening mandrel 10 internally within wall 40. The other flange of section 46 together with another flange of the adjacent cylindrical section (both flanges not shown) similarly bolt together and form another circumferential rib. Still other cylindrical sections similarly bolt together and provide like circumferential ribs spaced axially from one another along cylindrical section 15 within wall 40.
Between flanges 50,52 axially along cylindrical section 44 are spaced circumferential ribs 60,62 (see also FIG. 2) which provide further strengthening for the portion of thin wall 40 between flanges 50,52. Other similarly disposed circumferential ribs in cylindrical sections 46,48 and others similarly strengthen wall 40 of cylindrical section 15.
Spaced longitudinal ribs 64 of cylindrical section 44 extend axially between circumferential ribs 50,52 and intersect ribs 60 and 62. Longitudinal ribs 64 (all 24 depicted in FIG. 2) are welded to the inner side of wall 40 and provide axial reinforcement of cylindrical section 44. Other longitudinal ribs 66 of section 46, shown in part in FIGS. 1 and 4, align with longitudinal ribs 64. Ribs 66 and others within cylindrical section 15 of mandrel 10 align with ribs 64 to provide continuous axial reinforcements spaced circumferentially about the inside of wall 40 axially along mandrel 10.
FIG. 5 depicts diagramatically a partial cross section of the wall 67 of a filament wound mandrel made in accordance with this invention. The cross section is taken along the center longitudinal axis of mandrel 10 and includes a section of wall 40 thereof.
Each of level layers 68A through 68K of the cross section depicts a ply of continuous filamentary graphite materials that has been wound relatively circumferentially (about 85°-90° to the center longitudinal axis of mandrel 10) about mandrel 10. Each ply has about 14 tows/inch. Each tow has about 12000 graphite filaments in an untwisted bundle and an area of between about 6 and 9×10 -4 inches. Level layers 68A-68C each provide a maximum thickness change in wall section 67 of about 0.027 inches after their respective winding around mandrel 10. Level layers 68D-68K each provide a thickness change of about 0.024 inches after their respective winding around mandrel 10.
Each of helical layers 70A through 70J depicts a pair of plies of filamentary graphite materials that has been wound relatively highly axially (about ±10° to the center longitudinal axis of mandrel 10) about mandrel 10. Each of the plies has about 46 tows per inch wherein the tow is defined above and is at an angle that is the negative of its partner. The thickness change in wall section 67 caused by winding each of helical layers 70A through 70C around mandrel 10 is a maximum of about 0.158 inches and about 0.130 inches for each of layers 78D-78J.
The thickness of wall section 67 totals about 3.2 centimeters. The outer diameter of the wall of the filament wound mandrel is about 101.4 inches after completion of the windings. The tension of the filamentary materials used in winding layers 68A through 68K is about 4 to 8 pounds force. The tension on the filamentary materials used in winding layers 70A through 70J is about 2 to 3 pounds force.
Layer 72 in FIG. 5 is a cloth layer made from graphite fiber or the like and has a thickness of about 0.035 inches The preferred cloth is epoxy resin impregnated cloth having a high strength modulus The resin content is between about 39% and 45% by weight with a fiber volume of between about 59% and 65%. The fiber weighs about 350-400 grams per square meter. The cloth may be a 5 or 8 harness weight and 11 by 11 or 21 by 21 with a 3000 or 6000 end weave.
Doubler sections (i.e., wall sections of thicker or thinner cross section) can be fabricated at the ends of the structures of this invention as desired and have, for example, several plies of both S2 glass fiber and graphite fiber that alternate with one another above layer 68K. Between doublers at the ends graphite prepreg tape 68 may be applied using 75 pounds force per 2 inch tape.
In a first practice in accordance with this invention, level layers 68A through 68C incorporate a relatively non-gelling epoxy winding resin that remains at relatively low viscosity until curing. The non-gelling epoxy winding resin comprises (a) 100 parts by weight epoxy resin polymers, (b) about 35-40 parts by weight of a diaminodiphenylsulfone and (c) about 2-10 parts by weight of a piperidine and boron trifluoride complex.
The epoxy resin polymers are preferably a combination of epoxy polymers in which one acts as a reactive diluent. The combination comprises (i) between about 70 and 90 parts by weight of a diglycidal ether of bisphenol A epoxy polymer; and (ii) between about 10 and 30 parts by weight of a 1,4-butanediol epoxy polymer which is a reactive diluent for (i).
The bisphenol A epoxy polymer (i) has an epoxy equivalent weight between about 180-190 grams and a viscosity of between about 70-100 cp at 25° C. The reactive diluent has an epoxy equivalent weight of between about 125 and 150 grams, a viscosity of between about 10 and 25 cp at 25° C. and a specific gravity of between about 1.09 and 1.11 at 25/25° C. The epoxy resin polymer combination (i.e. (i) and (ii) together) has a viscosity between about 700 and 900 cp at 25° C., an epoxy equivalent weight of between about 167 and 176 grams and a specific gravity of between about 1.13 and 1.15 at 25/25° C. The epoxy resin polymers (i.e. (i) and (ii) combined) is available as EPON 826/EPI RE 25022 from Dexter Corp., Pittsburgh, CA. The diaminodiphenylsulfone is preferably 4,4' diaminodiphenylsulfone (DAPS) having a melting point between about 170 and 180° C. available, for example, as Eporal from Ciba-Geigy, Ardsley, N.Y. The piperidine complex of boron trifluoride is in the tan, solid form having a final melting temperature of between about 70°-75° C. available, for example, from Harshaw Chemical, Cleveland OH as BF 3 -PIP.
The non-gelling epoxy winding resin has a viscosity between about 500 cp and 7500 cp at 25° C., a gel time at 150° C. of between about 15-30 minutes, a working life at 38° C. of at least about 12 hours and a density of between about 9 and 11 lb./gal. The non-gelling epoxy winding resin has a designation of MX-16 Epoxy Resin System by Hercules Incorporated, Magna, Utah.
Level layers 68D through 68K and helical layers 70D through 70J in the earlier mentioned first practice incorporate a gelling epoxy winding resin that gels below about 40° C. The gelling epoxy resin has 125 parts by weight of the epoxy polymers as described above in (a) of the non-gelling epoxy winding resin with about 25-35 parts weight of an amine blend curing agent. The amine blend curing agent has between about 35 and 45 parts by weight m-phenylenediamine (MPDA), between about 30 and 40 parts by weight p,p'-methylenedianiline (4,4 MDA), and between about 5 and 10 parts by weight o,p-methylenedianiline (2,4' MDA) with a titratable nitrogen content between about 18 and 19% by weight and less than 0.4 percent water. The amine blend can be obtained as Tonox 6040 from Uniroyal Incorporated, Naugatuck, CT. The pot life of the gelling winding epoxy resin is about four hours. The curing agent is added to the resin with the former being at a temperature of between about 100 and 120° F. and the latter between about 60 and 100° F.
In other practices of this invention, layers 68A-68K and 70A-70J are all wound using the gelling epoxy winding resin.
The filamentary materials employed in level and helical layers 68A-68K and 70A-70J are preferably the filamentary graphite materials that have about 12000 filaments per tow, i.e, a bundle of continuous filaments that are not twisted. These filamentary materials can be obtained from Hercules Incorporated, Magna, Utah as AS-4 graphite fiber or AS-4W graphite fiber which is the AS-4 graphite fiber coated with an epoxy sizing agent (Hercules Type W). These graphite fibers are manufactured by exposing polyacrylonitrile (PAN) to highly elevated temperature and have a density of between about 0.0625 and 0.0660 lb/square inch, a size content of between about 0.6 and 1.2% by weight, and respective ultimate tensile strength and modulus of elasticity (expressed at 100% fiber volume) of at least about 385 psi and between about 32 and 35 million psi at 77° F. The weight per length of the fiber is between about 43 and 52×10 -6 lb/inch.
The non-gelling and gelling epoxy winding resins are respectively combined with the graphite or other such filamentary materials at about 36 and 44% by weight resin to about 56 and 64% by weight filamentary solids. The impregnated filamentary graphite materials for layers 68A-68K and 70A-70J weigh between about 0.437 and 0.475 grams per linear foot per tow in the former resin case and between about 0.444 and 0.467 grams per linear foot per tow in the latter resin case.
After each pair of plies of the helical layers 70A-70J is wound, it undergoes radial compression inwardly prior to application of the succeeding layer of the level layers 68A-68K. The radial compression can be with a highly tensioned sacrificial tape; or it can be with a continuous, highly tensioned belt.
If a sacrificial tape is employed, the tape can be in the form of a thin, two inch ribbon that is porous. The ribbon is circumferentially wrapped (relative to the center longitudinal axis of mandrel 10) under tension about mandrel 10 over each pair of the plies of helical layers 70A-70J. An example of such tape is the teflon coated woven glass tape marketed as 384-8/60, style 125 from Fluorglas Division, Oak Materials Group, Hoosick Falls, N.Y.
The sacrificial tape is wound about mandrel 10 over each pair of plies at a minimum of about 90 pounds force tension per inch width of the tape; it is as overlapped approximately half its width. As a level layer of 68A-68K that is to be wound about the temporarily bound pair of plies is wound, portions (normally about 2 ribbon widths or about 3-4 inches) of the sacrificial tape, which portions are axially adjacent to the level layer portion being wound, are unwound. In a variant form, the tape is wound and unwound as the succeeding level layer is wound about the pair of plies of the helical layer. In this variation, the pair of plies of the helical layer has a wrapping of two or three ribbon widths (about 3 to 5 inches wide) of the tape wound about it at any one time.
A continuous belt apparatus or the like may be used as an alternative to the use of sacrificial tape. The belt apparatus employs a tensioned belt looped around a portion of the pair of plies, such as the pair of plies of helical layer 70A, that continually changes axially as mandrel 10 rotates. The portion in contact with the belt is radially compressed toward wall 40 of mandrel 10 first by the belt, and then by filamentary materials of the succeeding level layer as another, axially adjacent, portion of the pair of plies comes into contact with the belt. The belt contacts the pair of plies at an angle such that there is rotation of mandrel 10 and axial translation of the belt relative to the mandrel.
When using gelling or non-gelling epoxy winding resins as described above, the time for winding each of helical layers 70A through 70J ranges preferably up to about 24 hours from start to completion of compaction by the aforedescribed belt or tape for optimum usage of these resins. If the preceding layer is no longer tacky because of delay, however, such preceding layer can be refreshed by application of the appropriate resin.
After completion of winding level layers 68A-68K and helical layers 70A-70J about mandrel 10, the filament wound mandrel is placed in an oven. Generally, the temperatures and times employed in curing operations include temperatures in a range between about 200 and 400° F. and periods of between 10 and 15 hours when the aforedescribed epoxy winding resins are used. A typical cure schedule (using the above described graphite fiber and epoxy winding resins) is to (1) raise the temperature of the filament wound mandrel to between about 235° and 265° F. in two hours, (2) hold at about this temperature for about three hours, then (3) raise the temperature to between about 335° and 365° F. in about two and one half hours, (4) hold at this latter temperature for about three hours and (5) then cool to between about 135° and 165° F. at a rate not exceeding about 50° F. per hour. The temperature inside the mandrel is greater than that of the oven outside the mandrel during substantially the entire time of at least steps (1) and (2), by at least about 5° F., more preferably also during steps (3) and (4). The temperature of the filament wound part itself, however, is kept substantially uniform, preferably not varying more than about 10°-25° F. from location to location and more preferably less. Use of a same cure schedule from filament wound mandrel to filament wound mandrel provides for structures with reproducable dimensions.
When the average temperature of the structure declines to between about 135° and 165° F. during cooling, the structure is removed from the oven and allowed to further cool by natural convection. While in the oven, mandrel 10 oscillates at a rate of up to about 3 rpm.
In curing operations of this invention, as mentioned, the temperatures inside mandrel 10 are greater by at least about 5° F. than the temperatures of the oven outside the filament wound mandrel at each curing stage. To this end, banks of radiant heaters are carried within mandrel 10 on a hollow, cylindrical metal tube or shaft of constant diameter extending between ends 12,12' through ring flanges 28,28'.
The metal tube or shaft is inserted after completion of the winding of the filamentary materials about mandrel 10. End cap 18 is unfastened and removed to allow mounting of the shaft within mandrel 10 along its center longitudinal axis. The shaft carries two or more heater banks between ends 12,12' of mandrel 10 within cylindrical section 15. Each heater bank comprises six radiant heaters that are mounted to and spaced around the exterior of the shaft. Each radiant heater extends longitudinally along the shaft in each bank coextensively with the others of that bank. Electrical wires for the heaters extend inside the shaft. The ends of the shaft mount through flanges 28,28 inside hubs 20,20'. The middle portion of the shaft is mounted to the inside of cylindrical section 15 by guides that attach to a circumferential rib in the interim of mandrel 10. Strategically located thermocouples (e.g. within mandrel 10 and within the alternate layers of windings) sense temperatures and heating elements of the radiant heaters are controlled in response thereto.
After the structure has cured in accordance with a schedule such as aforementioned and is at room temperature, it is slid from the mandrel axially. One of pin rings 32,32' is unfastened and removed from mandrel 10 as is the roll bar 12 or 12' adjacent thereto. The end of mandrel 10 with pin ring and roll bar removed is fixed and the other end supported under the cured structure. Hydraulic rams are spaced about the structure against the end of its wall at the fixed end of mandrel 10 and push the structure off mandrel 10 while it is supported by an air palet at the other.
Present and prospective specific applications for the tubular structures made in accordance with practices of this invention include canisters for strategic missiles and fuel confinement vessels for space vehicles.
This invention has been described by relatively detailed reference to a specific practice thereof. It is to be understood that these details of the disclosure are not meant as a limitation of the scope of this invention, but, rather as means for enabling its broader usage. Other particulars useful in its practice will be recognized by those familiar with the art of filament winding.
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This invention relates to an improvement in filament winding large, hollow, tubular structures having significant axial reinforcement in their thick walls by means including (a) using a hollow, light weight mandrel adapted to expand radially at elevated temperatures and windings of alternate layers of filamentary materials positioned substantially axially and substantially circumferentially relative to the longitudinal axis of the mandrel wherein the alternate layers are preferably in a certain thermosettable resin matrix and wound in certain fashion and (b) heating the filament wound mandrel to cure the thermosettable resin wherein heat from inside and out of the mandrel controls the cure and expansion during the heating step. The thick walls preferably incorporate graphite fibers for significant strength in the reinforcement provided by the filamentary materials.
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REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Patent Application No. 60/754,161, entitled “Method for Forming Self-Aligned Thermal Isolation Cell for a Phase Change Memory Array” filed on 27 Dec. 2005. That application is incorporated by reference for all purposes.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to non-volatile memory structures, and more specifically to memory devices employing Resistance Random Access Memory (RRAM) memory elements.
2. Description of Related Art
RRAM based memory materials are widely used in read-write optical disks and non-volatile memory arrays. These materials have at least two solid phases, including for example a generally amorphous solid phase and a generally crystalline solid phase. Laser pulses are used in read-write optical disks to switch between phases and to read the optical properties of the material after the RRAM.
RRAM based memory materials, such as chalcogenide based materials and similar materials, also can be caused to change phase by application of electrical current at levels suitable for implementation in integrated circuits. The generally amorphous state is characterized by higher resistivity than the generally crystalline state, which can be readily sensed to indicate data. These properties have generated interest in using programmable resistive material to form nonvolatile memory circuits, which can be read and written with random access.
The change from the amorphous to the crystalline state is generally a lower current operation. The change from crystalline to amorphous, referred to as reset herein, is generally a higher current operation, which includes a short high current density pulse to melt or breakdown the crystalline structure, after which the RRAM material cools quickly, quenching the RRAM process, allowing at least a portion of the RRAM structure to stabilize in the amorphous state. It is desirable to minimize the magnitude of the reset current used to cause transition of RRAM material from crystalline state to amorphous state. The magnitude of the reset current needed for reset can be reduced by reducing the size of the RRAM material element in the cell and of the contact area between electrodes and the RRAM material, so that higher current densities are achieved with small absolute current values through the RRAM material element.
One direction of development has been toward forming small pores in an integrated circuit structure, and using small quantities of programmable resistive material to fill the small pores. Patents illustrating development toward small pores include: Ovshinsky, “Multibit Single Cell Memory Element Having Tapered Contact,” U.S. Pat. No. 5,687,112, issued Nov. 11, 1997; Zahorik et al., “Method of Making Chalogenide [sic] Memory Device,” U.S. Pat. No. 5,789,277, issued Aug. 4, 1998; Doan et al., “Controllable Ovonic Phase-Change Semiconductor Memory Device and Methods of Fabricating the Same,” U.S. Pat. No. 6,150,253, issued Nov. 21, 2000.
Problems have arisen in manufacturing such devices with very small dimensions, and with variations in process that meets tight specifications needed for large-scale memory devices. It is desirable therefore to provide a memory cell structure having small dimensions and low reset currents, and a method for manufacturing such structure that meets tight process variation specifications needed for large-scale memory devices. It is further desirable to provide a manufacturing process and a structure, which are compatible with manufacturing of peripheral circuits on the same integrated circuit.
SUMMARY OF THE INVENTION
A non-volatile memory device with a self-aligned RRAM element. The memory device includes a lower electrode element, generally planar in form, having an inner contact surface. At the top of the device is an upper electrode element, spaced from the lower electrode element. A containment structure extends between the upper electrode element and the lower electrode element, and this element includes a sidewall spacer element having an inner surface defining a generally funnel-shaped central cavity, terminating at a terminal edge to define a central aperture; and a spandrel element positioned between the sidewall spacer element and the lower electrode, having an inner surface defining a thermal isolation cell, the spandrel inner walls being spaced radially outward from the sidewall spacer terminal edge, such that the sidewall spacer terminal edge projects radially inward from the spandrel element inner surface. A RRAM element extends between the lower electrode element and the upper electrode, occupying at least a portion of the sidewall spacer element central cavity and projecting from the sidewall spacer terminal edge toward and making contact with the lower electrode. In this manner, the spandrel element inner surface is spaced from the RRAM element to define a thermal isolation cell adjacent the RRAM element.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an embodiment of a variable resistance memory element as claimed herein.
FIG. 1 a depicts the sidewall portion of the embodiment of FIG. 1 .
FIGS. 2 a - 2 h illustrate an embodiment of a process for fabricating the embodiment of FIG. 1 .
DETAILED DESCRIPTION
The following detailed description is made with reference to the figures. Preferred embodiments are described to illustrate the present invention, not to limit its scope, which is defined by the claims. Those of ordinary skill in the art will recognize a variety of equivalent variations on the description that follows.
A memory element 10 is illustrated in FIG. 1 . The element is fabricated on a substrate, or inter-layer dielectric layer, 12 . The following discussion sets out the structure of this element, with the fabrication process following shortly thereafter. This layer preferably consists of silicon oxide or a well-known alternative thereto, such as a polyimide, silicon nitride or other dielectric fill material. In embodiments, the dielectric layer comprises a relatively good insulator for heat as well as for electricity, providing thermal and electrical isolation. An electrical contact, or plug, 14 , preferably formed from a refractory metal such as tungsten, is formed in the oxide layer. Other refractory metals include Ti, Mo, Al, Ta, Cu, Pt, Ir, La, Ni, and Ru. The plug element makes electrical contact with an isolation or switching device, such as a transistor, located below the dielectric layer 12 , as is known in the art. Other circuit components preferably located below the illustrated RRAM element include the common source lines and word lines, both of which are well-known in the memory art.
It should be noted that, for purposes of reference only, the direction from the bottom toward the top of the drawings herein is designated “vertical”, and the side-to-side direction is “lateral” or “horizontal.” Thus, “width” denotes a dimension parallel to the horizontal direction in the drawings, and “height” or “thickness” denotes a dimension parallel to the vertical. Such designations have no effect on the actual physical orientation of a device, either during fabrication or during use.
An lower electrode element 16 is formed atop the plug element 14 . The lower electrode is preferably generally tabular in form and can be slightly wider than the plug element. It is formed from a metal such as copper, but other types of metallization, including aluminum, titanium nitride, and tungsten based materials can be utilized as well. Also, non-metal conductive material such as doped polysilicon can be used. The electrode material in the illustrated embodiment is preferably TiN or TaN. Alternatively, the lower electrodes may be TiAlN or TaAlN, or may comprise, for further examples, one or more elements selected from the group consisting of Ti, W, Mo, Al, Ta, Cu, Pt, Ir, La, Ni, and Ru and alloys thereof.
A spandrel element 18 is formed on the lower electrode element. As will be understood better in considering the spandrel element in the context of the embodiment as a whole, the material of which this element is composed will depend on choices made for adjacent layers. In general it can be said that that the overall criteria for this element are that it first function effectively as a spandrel in the environment of a memory device, and second that it offer the possibility of a highly selective etching process, as described below. Thus, the material to be employed here depends upon the materials chosen for the lower electrode element 16 , discussed above, and the sidewall spacer element 21 , discussed above. If, for example, the lower electrode element is composed of TiN, as is preferable, then suitable materials for the spandrel element could be W or Al or SiN, all of which offer the possibility of a high differential etch rate, as discussed below.
Sidewall spacer element 21 lies above and in contact with the spandrel element. This element is relatively thick compared with the lower electrode and spandrel, but it is coextensive with those elements in width. FIG. 1 a is a detailed view of the sidewall spacer element, allowing its structure to be viewed more clearly. As can be seen there, the sidewall spacer element has a central cavity 32 , generally funnel-shaped in form, with inner sides 38 of the sidewall spacer having a convex profile. The inner sides intersect with the bottom of the sidewall spacer to form terminal edges 34 , which in turn define a central aperture 36 . The sidewall spacer element is formed from a dielectric fill material.
As shown in FIG. 1 , a portion of the sidewall spacer central cavity is filled with a RRAM element 22 . This element fills the lower portion of the central cavity and extends downward to make contact with the lower electrode element.
The phase-change element 22 is formed from a material that can assume at least two stable resistance levels, referred to as resistance random access memory (RRAM) material. Several materials have proved useful in fabricating RRAM, as described below.
An important class of RRAM material is the chalcogenide group. Chalcogens include any of the four elements oxygen (O), sulfur (S), selenium (Se), and tellurium (Te), forming part of group VI of the periodic table. Chalcogenides comprise compounds of a chalcogen with a more electropositive element or radical. Chalcogenide alloys comprise combinations of chalcogenides with other materials such as transition metals. A chalcogenide alloy usually contains one or more elements from column six of the periodic table of elements, such as germanium (Ge) and tin (Sn). Often, chalcogenide alloys include combinations including one or more of antimony (Sb), gallium (Ga), indium (In), and silver (Ag). Because chalcogenides achieve their dual-memory capabilities by forming two solid phases, each of which exhibits a characteristic resistance, these materials are referred to as “RRAM” materials or alloys.
Many RRAM based memory materials have been described in technical literature, including alloys of: Ga/Sb, In/Sb, In/Se, Sb/Te, Ge/Te, Ge/Sb/Te, In/Sb/Te, Ga/Se/Te, Sn/Sb/Te, In/Sb/Ge, Ag/In/Sb/Te, Ge/Sn/Sb/Te, Ge/Sb/Se/Te and Te/Ge/Sb/S. In the family of Ge/Sb/Te alloys, a wide range of alloy compositions may be workable. The compositions can be characterized as Te a Ge b Sb 100−(a+b) . One researcher has described the most useful alloys as having an average concentration of Te in the deposited materials well below 70%, typically below about 60% and ranged in general from as low as about 23% up to about 58% Te and most preferably about 48% to 58% Te. Concentrations of Ge were above about 5% and ranged from a low of about 8% to about 30% average in the material, remaining generally below 50%. Most preferably, concentrations of Ge ranged from about 8% to about 40%. The remainder of the principal constituent elements in this composition was Sb. These percentages are atomic percentages that total 100% of the atoms of the constituent elements. (Ovshinsky '112 patent, cols 10-11.) Particular alloys evaluated by another researcher include Ge 2 Sb 2 Te 5 , GeSb 2 Te 4 and GeSb 4 Te 7 . (Noboru Yamada, “Potential of Ge—Sb—Te Phase-Change Optical Disks for High-Data-Rate Recording”, SPIE v. 3109, pp. 28-37 (1997).) More generally, a transition metal such as chromium (Cr), iron (Fe), nickel (Ni), niobium (Nb), palladium (Pd), platinum (Pt) and mixtures or alloys thereof may be combined with Ge/Sb/Te to form a RRAM alloy that has programmable resistive properties. Specific examples of memory materials that may be useful are given in Ovshinsky '112 at columns 11-13, which examples are hereby incorporated by reference.
RRAM alloys are capable of being switched between a first structural state in which the material is in a generally amorphous solid phase, and a second structural state in which the material is in a generally crystalline solid phase in its local order in the active channel region of the cell. These alloys are at least bistable. The term amorphous is used to refer to a relatively less ordered structure, more disordered than a single crystal, which has the detectable characteristics such as higher electrical resistivity than the crystalline phase. The term crystalline is used to refer to a relatively more ordered structure, more ordered than in an amorphous structure, which has detectable characteristics such as lower electrical resistivity than the amorphous phase. Typically, RRAM materials may be electrically switched between different detectable states of local order across the spectrum between completely amorphous and completely crystalline states. Other material characteristics affected by the change between amorphous and crystalline phases include atomic order, free electron density and activation energy. The material may be switched either into different solid phases or into mixtures of two or more solid phases, providing a gray scale between completely amorphous and completely crystalline states. The electrical properties in the material may vary accordingly.
RRAM alloys can be changed from one phase state to another by application of electrical pulses. It has been observed that a shorter, higher amplitude pulse tends to change the RRAM material to a generally amorphous state. A longer, lower amplitude pulse tends to change the RRAM material to a generally crystalline state. The energy in a shorter, higher amplitude pulse is high enough to allow for bonds of the crystalline structure to be broken and short enough to prevent the atoms from realigning into a crystalline state. Appropriate profiles for pulses can be determined, without undue experimentation, specifically adapted to a particular RRAM alloy. In following sections of the disclosure, the RRAM material is referred to as GST, and it will be understood that other types of RRAM materials can be used. A material useful for implementation of a PCRAM described herein is Ge 2 Sb 2 Te 5 .
Other programmable resistive memory materials may be used in other embodiments of the invention. One such material is a colossal magnetoresistance (CMR) material, which dramatically change resistance levels in the presence of a magnetic field. Such materials are generally manganese-based perovskite oxides, and the resistance changes encountered are generally in the range of orders of magnitude. A preferred formulation for RRAM applications is Pr x Ca y MnO 3 , where x:y=0.5:0.5, or other compositions in which x:0˜1; y:0˜1. Other CMR materials including an Mn oxide can also be employed.
Another RRAM material is a 2-element compound, such as Ni x O y ; Ti x O y ; Al x O y ; W x O y ; Zn x O y ; Zr x O y ; Cu x O y , where x:y=0.5:0.5. Alternatively, another compound in this group could be employed, in which x:0˜1; y:0˜1. Also, polymers employing dopants such as Cu, C60, Ag can be employed, including 7,7,8,8-tetracyanoquinodimethane (TCNQ), methanofullerene 6,6-phenyl C61-butyric acid methyl ester (PCBM), TCNQ-PCBM, Cu-TCNQ, Ag-TCNQ, C60-TCNQ, TCNQ doped with other metal, or any other polymer material that has bistable or multi-stable resistance state controlled by an electrical pulse.
Here the relationship between the sidewall spacer element, the RRAM element, the spandrel element and the lower electrode element should be noted. The spandrel element lies between the lower electrode and sidewall spacer elements, but the inner edges 19 of the spandrel element do not extend to make contact with the lower portion of the RRAM element. Rather, the spandrel inner edges are recessed from the sidewall spacer element terminal edges, so that the sidewall spacer, spandrel, lower electrode and RRAM elements enclose a void surrounding the RRAM element, thermal isolation cell 20 . The spandrel element is surrounded by an inter-metal dielectric layer 24 , which is preferably a dielectric fill material, such as SiO2.
Upper electrode element 26 lies on the sidewall spacer element, and a portion of the upper electrode extends into the central cavity to make electrical contact with RRAM element 22 . This element is preferably formed from TiN or similar material, as discussed above. This electrode provides contact with other circuit elements, and in one embodiment it is in direct electrical contact a bit line (not shown).
Operation of the embodiment of FIG. 1 proceeds as follows. As noted above, the memory element 10 stores a data bit by altering the solid phase of RRAM element 22 , causing the electrical resistance of that device to change as well. In its crystalline phase state, the RRAM element has a relatively low electrical resistance, while in the amorphous state its resistance is relatively high. Thus, one state can be chosen to represent a logical one and the other a logical zero, also referred to in the art as “high” and “low” logic levels. Thus, two signals are required to set the device state, a SET signal and one for RESET, chosen to produce the desired RRAM in the element. In one embodiment, the default level for the device is chosen to be the logical zero, or low, which is chosen to correspond to the high resistance (amorphous) state. Thus, the RESET signal is chosen as appropriate to produce the amorphous state. The SET signal, to produce the logic one level, is likewise chosen to produce the crystalline state. One other operation must be provided for, to sense a present level of the device in a READ operation. That signal is chosen below the level that will produce any RRAM.
These signals are generally initiated in control circuitry (not shown) which communicates with the circuitry immediately concerned with the memory element shown. In one embodiment such initiation proceeds by energizing the word line associated with the transistor controlling the element, turning that transistor on so that current flows through the transistor to plug element 14 and then through lower electrode 16 , RRAM element 22 and upper electrode 26 and out to the bit line (not shown). That high current density in the most narrow area 28 of RRAM element 22 produces joule heating, which in turn leads to RRAM. The area 28 is by design located in the area of thermal isolation cell 20 .
An embodiment of the process for fabricating the memory element of FIG. 1 is shown in FIGS. 2 a - 2 h . Discussions above on the materials employed will not be repeated here.
The process begins with deposition of the substrate, or inter-layer dielectric (ILD) 12 , as depicted in FIG. 2 a . Next, the plug element 14 is formed through the ILD, preferably by lithographically etching the opening and depositing the electrode material, followed by planarizing the ILD to remove any excess electrode material. Then three layers are deposited in succession—an electrode layer 16 , a spandrel layer 18 and a sacrificial layer 23 . Deposition of these layers can proceed as known in the art. The sacrificial layer 23 is preferably composed of silicon nitride, primarily for its ability to be preferentially etched in comparison with silicon dioxide. Following deposition, the width of these three layers is trimmed to a desired value, preferably employing conventional lithographic and etching methods.
Next, as seen in FIG. 2 c , an inter-metal dielectric layer (IMD) 24 is deposited or grown on the ILD, surrounding the trimmed layers. This layer is composed of suitable dielectric fill material, as discussed above. A planarization process, such as chemical-mechanical polishing (CMP) is employed to reduce the thickness of the newly-formed dielectric layer to a desired thickness, exposing the nitride layer 23 . Next, as seen in FIG. 2 d , the nitride layer is removed, leaving a void 27 in the upper surface of the IMD.
FIG. 2 e depicts the initial formation of sidewall spacer 21 , which is formed by deposition followed by etching, to produce a structure having a profile with convex sides of increasing thickness from top to bottom. Those in the art will understand that a number of known processes exist to accomplish this step, including the technique of sidewall spacer patterning. To accomplish that result, a layer of suitable material, such as an oxide dielectric material, is deposited on the structure shown in FIG. 2 d . That material is then anisotropically etched to remove all material down to the level of the IMD 24 , leaving a sidewall spacer 21 having sloping walls and a funnel-shaped central cavity 32 , as discussed above. The etchant for this process is dependent on the exact materials, but assuming the spandrel 18 is W, then the preferred etchant for the oxide material is CHF 3 /CHF 4 or CH 3 F/CHF 4 . either of those choices is highly selective for the oxide over the tungsten material.
In the next step, the thermal isolation cell is formed, as shown in FIG. 2 f . Preferably, this etching step is performed via a plasma etch, using a no-bias, isotropic process. Here the preferred etchant is SF 6 /O 2 , which will etch the oxide and TiN layers at a significantly slower rate than the W material of the spandrel. Of course, different materials will require a change in the etch material recipe.
The etchant acts selectively on the spandrel, leaving the sidewall spacer and underlying electrode relatively unaffected. The result is that the spandrel element is removed altogether in its central portion, with inner edges 19 substantially recessed from the central opening of the sidewall spacer.
Next, in FIG. 2 g , the RRAM element 22 is added, preferably by a deposition process. Here it is preferred to carry out the deposition with a sputtering process, which will produce a more conformal coating. Owing to the inward-sloping shape of the sidewall spacer, and its central opening, deposited GST material accumulates on the upper surface of electrode 16 , building upward until it reaches the level of the sidewall spacer central opening, and thereafter the GST material proceeds to fill the sidewall spacer central cavity. It is preferred to continue the GST deposition until the sidewall spacer is filled, which also produces a layer of GST material on the ILD layer. A selective etching step is then undertaken, which removes all GST material on the ILD layer. In one embodiment, the etch is continued until the GST material is recessed into the sidewall spacer central cavity, as shown in FIG. 2 g . This measure is preferred in order to ensure good contact between the RRAM element and the succeeding layer, as explained below. After this step, the RRAM element 22 is a flared shape, with its narrow end in contact with electrode 16 . As a further consequence of the operations on the sidewall spacer, the RRAM element is self-aligned in the cell, centered on the electrode. Also, it is desirable that the narrowest segment of the RRAM element be just below the terminal edge of the sidewall spacer, and the sidewall spacer geometry can be designed to provide that result, as shown.
The final step is shown in FIG. 2 h , in which the upper electrode 26 is deposited. This element, formed of TiN, as discussed above, is deposited, according to methods known in the art, so that material fills the remainder of the sidewall spacer, making contact with the RRAM element, and then forms a layer atop the ILD. The layer is reduced to a desired thickness, preferably using a CMP process, and then lithographically trimmed to a desired width, with the result as shown.
While the present invention is disclosed by reference to the preferred embodiments and examples detailed above, it is to be understood that these examples are intended in an illustrative rather than in a limiting sense. It is contemplated that modifications and combinations will readily occur to those skilled in the art, which modifications and combinations will be within the spirit of the invention and the scope of the following claims.
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A non-volatile method with a self-aligned RRAM element. The method includes a lower electrode element, generally planar in form, having an inner contact surface. At the top of the device is a upper electrode element, spaced from the lower electrode element. A containment structure extends between the upper electrode element and the lower electrode element, and this element includes a sidewall spacer element having an inner surface defining a generally funnel-shaped central cavity, terminating at a terminal edge to define a central aperture; and a spandrel element positioned between the sidewall spacer element and the lower electrode, having an inner surface defining a thermal isolation cell, the spandrel inner walls being spaced radially outward from the sidewall spacer terminal edge, such that the sidewall spacer terminal edge projects radially inward from the spandrel element inner surface. ARRAM element extends between the lower electrode element and the upper electrode, occupying at least a portion of the sidewall spacer element central cavity and projecting from the sidewall spacer terminal edge toward and making contact with the lower electrode. In this manner, the spandrel element inner surface is spaced from the RRAM element to define a thermal isolation cell adjacent the RRAM element.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for producing a denaturated manganese dioxide catalyst for the hydration reaction of cyanohydrins. More particularly, the present invention relates to a process for producing efficiently manganese dioxide having a high catalytic activity for the hydration reaction of cyanohydrin in an aqueous phase.
2. Description of the Related Arts
The reaction for synthesizing an amide from a corresponding nitrile can be applied, for example, to the production of acrylamide from acrylonitrile or the production of methyl methacrylate from acetone cyanohydrin by way of α-hydroxyisobutyric acid amide. The development of an excellent catalyst for the synthetic reaction of amides starting from the corresponding nitriles is of great significance from the industrial standpoint.
It has already been well known that manganese dioxide is used as a catalyst for the synthesis of an amide by the hydration reaction of a nitrile, and a variety of methods for preparing the catalyst have been proposed. For example, it is disclosed in West Germany Patent No. 1593320 that manganese dioxide is prepared by reacting manganese sulfate and potassium permanganate in an equivalent amount at a temperature of 80° C. in the presence of a little excessive amount of sodium hydroxide.
It is also disclosed in U.S. Pat. No. 4018829 that δ-type manganese dioxide is suitable for a catalyst in the hydration reaction of acetone cyanohydrin. The δ-type manganese dioxide, as described in Z. Anorg. Allg. Chem., 309 (1961), pages 10 to 14, is produced by the reduction of a manganese (VII) compound in the neutral to alkaline pH at a temperature of 20° to 100° C.
Moreover, as the production methods of amide compounds from nitriles, there are disclosed a method for utilizing a catalyst prepared by incorporating zinc into manganese dioxide which has been prepared from potassium permanganate and manganese sulfate in Japanese Patent Application Laid-Open No. 57534/1988 and a method for utilizing, as a catalyst, manganese dioxide which has been obtained by the reduction of an alkaline aqueous solution of potassium permanganese with hydrochloric acid in Japanese Patent Application Laid-Open No. 57535/1988.
Manganese dioxide prepared by the conventional methods as described above has problems that (1) a satisfactory yield of an amide as a target cannot be obtained when the manganese dioxide is directly used as a catalyst of the hydration reaction of cyanohydrins, (2) the activity of the manganese dioxide is insufficient and thus the amount of the catalyst to be used is increased, and (3) the catalytic activity is rapidly lowered during its repeated use. Accordingly, the aforementioned manganese dioxide catalyst has not yet been used in practice.
The present inventors have conducted research earnestly for the purpose of producing a manganese dioxide catalyst for the hydration reaction of cyanohydrins free from the aforementioned problems. Particularly, earnest research has been conducted on the requirements for preparing a manganese dioxide catalyst for the hydration reaction of cyanohydrins starting from a permanganate salt and a manganese (II) compound. As a result, it has been found that a denaturated manganese dioxide prepared with specified starting materials under a prescribed temperature condition exhibits an extremely high catalytic activity and a long lifetime as a catalyst. The present invention has been accomplished on the basis of such findings.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a high active manganese dioxide catalyst for the hydration reaction of cyanohydrins.
Another object of the present invention is to provide a manganese dioxide which has a high activity and a long lifetime as a catalyst for the hydration reaction of cyanohydrins.
A further object of the present invention is to provide efficiently an amide by the hydration reaction of corresponding cyanohydrins.
That is to say, the present invention provides a process for producing a denaturated manganese dioxide catalyst for the hydration reaction of cyanohydrins, which process comprises reacting a permanganate salt and a manganese (II) compound in an acidic aqueous solution at a temperature of 60° C. to 150° C.
DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention will be described in detail below.
Manganese dioxide is used in the hydration reaction of cyanohydrins as already described above, in which manganese dioxide has a general composition of MnO 1 .7 to MnO 2 and crystal structures such as α, β, γ, δ and ε. Furthermore, in manganese dioxide, a transition between respective phases or a change in the crystallinity occurs so that its structure is very complicated and varied. While manganese dioxide is present in nature, it is usually prepared by the oxidation of manganese (II) compounds or the reduction of permanganate (VII) salts on its use as a catalyst.
The process according to the present invention belongs to the process for preparing a denaturated manganese dioxide from an excessive amount of a permanganate (VII) salt and a manganese (II) compound in an acidic aqueous solution.
The aqueous solutions of permanganate salts generally have different reactivities depending on the properties of the solutions, particularly pH.
In the strong alkaline condition, the permanganate releases oxygen to produce manganic acid (VI) with the reaction of the equation (1):
4MnO.sub.4.sup.- +4OH.sup.- →4MnO.sub.4.sup.2- +2H.sub.2 O+O.sub.2 ( 1).
In the neutral or acidic condition, the permanganate gradually decomposes and releases oxygen to form manganese dioxide with the reaction of the equation (2):
4MnO.sub.4.sup.- +4H.sup.+ →4MnO.sub.2 +2H.sub.2 O+3O.sub.2 (2).
In this connection, the redox reaction of an aqueous permanganate solution proceeds according to the equation (3) under an acidic condition and according to the equation (4) under the neutral or alkaline condition:
MnO.sub.4.sup.- →Mn.sup.2+ (3); MnO.sub.4.sup.- →MnO.sub.2 (4).
In the acidic condition, manganese dioxide is produced by the reaction of the equation (5) (Guyard reaction):
2MnO.sub.4.sup.- +3Mn.sup.2+ +2H.sub.2 O→5MnO.sub.2 +4H.sup.+ (5).
Accordingly, in an acidic aqueous solution, manganese dioxide can be prepared by the reactions represented by the equations (2), (3) and (5) with an excessive amount of permanganate salt and a manganese (II) compound.
The term "permanganate salt" used herein means one or more compounds selected from lithium permanganate, sodium permanganate and potassium permanganate. The term "manganese (II) compound" means one or more compounds selected from manganese sulfate, manganese nitrate and manganese chloride.
The reaction is conducted at a temperature in the range of 60° to 150° C., preferably 70° to 130° C. in the present invention. If the reaction is carried out at a temperature lower than that specified above, the reaction rate becomes low. If the reaction is carried out at a temperature higher than that specified above, the catalytic activity of the resulting denaturated manganese dioxide is decreased.
In the reaction of the present invention, the molar ratio of the permanganate salt to the manganese (II) compound is not critical, and it is usually in the range of 1/1 to 5/1, preferably in the range of 1.2/1 to 3/1. The permanganate salt and the manganese (II) compound are used in the form of aqueous solutions and are respectively used in high concentrations within their ranges of solubility or within the ranges that will not affect stirring operation. For instance, if the permanganate salt is an aqueous solution of potassium permanganate, the aqueous solution is preferably in the concentration of 1 to 3 moles/liter. If the manganese (II) compound is an aqueous solution of manganese sulfate, the aqueous solution is preferably in the concentration of 2 to 4 moles/liter.
As the acid in the acidic aqueous solution in the present invention, there is used a mineral acid such as sulfuric acid, nitric acid, hydrochloric acid or the like, preferably sulfuric acid. The amount of the acid used is not specifically limited. It may be appropriately set depending on the situations and its molar ratio of the acid to the permanganate salt is in the range of 0.1/1 to 2/1, preferably in the range of 0.2/1 to 1/1.
In the present invention, the denaturated manganese dioxide prepared as above is isolated and formed into a tablet or molded by extrusion to give a catalyst for a fixed bed, or it can be used directly in the form of powder as a slurry catalyst, which is applied to a batchwise or continuous reactor for the hydration reaction of cyanohydrins.
Cyanohydrins to be used in the present invention include aliphatic cyanohydrins having 2 to 8 carbon atoms. Specific examples of the aliphatic cyanohydrins are glycolonitrile, lactonitrile, acetone cyanohydrin and methyl ethyl ketone cyanohydrin.
The denaturated manganese dioxide prepared according to the process of the present invention can develop a high activity with a long lifetime as a catalyst for the hydration reaction of cyanohydrins. It is also possible to produce efficiently an amide by the hydration reaction of the corresponding cyanohydrin with the aforementioned catalyst.
Accordingly, the process of the present invention is of great industrial significance.
The present invention is described below in more detail with reference to Examples. The present invention is not limited thereto.
EXAMPLE 1
(1) Preparation of catalyst
To a solution of 66.4 g (0.42 mole) of potassium permanganate dissolved in 250 ml of water, a mixture of 141 g (0.28 mole) of a 30% by weight aqueous manganese sulfate solution and 23.9 g of concentrated sulfuric acid were added rapidly at a temperature of 70° C., and the mixture was allowed to react.
The resulting precipitate was stirred at 90° C. for 3 hours, filtered and washed three times with 500 ml of water followed by drying overnight at 110° C. to give 65.9 g of a black mass of manganese dioxide as catalyst.
Hydration reaction
(2) The manganese dioxide obtained in the aforementioned paragraph (1) was ground and passed through a sieve to give particles having size of 10 to 20 mesh, which was packed in a glass tubular reactor equipped with a jacket and having an internal diameter of 10 mm. Warm water at 60° C. was flown through the jacket, and a raw material solution consisting of a mixture of 20 g of acetone cyanohydrin, 60 g of water and 20 g of acetone was passed through the reactor at a flow rate of 5 g/hr.
The reaction mixture after 5 hours had a composition of 23% by weight of α-hydroxyisobutyric acid amide, 0.1% by weight of acetone cyanohydrin, 21.0% by weight of acetone and 0.4% by weight of formaldehyde upon the determination by high performance liquid chromatography. Such yields correspond to the α-hydroxyisobutyric acid amide of 95% (based on the acetone cyanohydrin as the raw material).
The reaction was further continued for 1 week. As the result of the composition analysis of the reaction mixture for the second time, the yield of α-hydroxyisobutyric acid amide was 95%.
Comparative Example 1
(1) Preparation of catalyst
To a solution of 19.2 g (0.12 mole) of potassium permanganate dissolved in 120 ml of water, a solution of 22.2 g (0.10 to 0.086 mole) of manganese sulfate tetrahydrate to hexahydrate and 6.7 g of potassium hydroxide dissolved in 30 ml of water was added rapidly at a temperature of 70° C., and the mixture was allowed to react.
The resulting precipitate was stirred at 70° C. for 3 hours, filtered and washed three times with 200 ml of water followed by drying overnight at 110° C. to give 23.8 g of a brown mass of manganese dioxide as catalyst.
(2) Hydration reaction
A 3.5 g portion of the catalyst prepared in the aforementioned paragraph (1) was used to conduct the hydration reaction in the same manner as in Example 1.
As the result, the yields of α-hydroxyisobutyric acid amide after 5 hours and 1 week were 74% and 41%, respectively.
Comparative Example 2
(1) Preparation of catalyst
To a solution of 19 g (0.12 mole) of potassium permanganate dissolved in 200 ml of water, a solution of 22.2 g (0.1 to 0.086 mole) of manganese sulfate tetrahydrate to hexahydrate and 10.2 g of concentrated sulfuric acid dissolved in 60 ml of water was added at a temperature of 50° C. over a period of 10 minutes, and the mixture was allowed to react.
The resulting precipitate was stirred at 50° C. for 10 hours, filtered and washed three times with 200 ml of water followed by drying overnight at 110° C. to give 23.1 g of a brown mass of manganese dioxide as catalyst.
(2) Hydration reaction
A 3.4 g portion of the catalyst prepared in the aforementioned paragraph (1) was used to conduct the hydration reaction in the same manner as in Example 1.
As the result, the yields of α-hydroxyisobutyric acid amide after 5 hours and 1 week were 58% and 11%, respectively.
Comparative Example 3
(1) Preparation of catalyst
To a solution of 12.6 g (0.08 mole) of potassium permanganate dissolved in 120 ml of water, a solution of 22.2 g (0.1 to 0.086 mole) of manganese sulfate tetrahydrate to hexahydrate and 2.5 g of concentrated sulfuric acid dissolved in 30 ml of water was added rapidly at a temperature of 70° C., and the mixture was allowed to react.
The resulting precipitate was stirred at 70° C. for 3 hours, filtered and washed three times with 200 ml of water followed by drying overnight at 110° C. to give 18.4 g of a black mass of manganese dioxide as catalyst.
(2) Hydration reaction
A 3.5 g portion of the catalyst prepared in the aforementioned paragraph (1) was used to conduct the hydration reaction in the same manner as in Example 1.
As the result, the yields of α-hydroxyisobutyric acid amide after 5 hours and 1 week were 94% and 62%, respectively.
EXAMPLE 2
(1) Preparation of catalyst
A 12.8 g amount of potassium permanganate was dissolved in 140 ml of water, and 2.5 g of concentrated sulfuric acid was added thereto.
To the resulting solution was added 22.2 g of manganese sulfate tetrahydrate to hexahydrate dissolved in 30 ml of water at a temperature of 70° C., and the mixture was allowed to react. Agitation was continued for 3 hours at 80° C. The mixture was cooled to room temperature, filtered and washed three times with 200 ml of water followed by drying overnight at 110° C. to give 22.5 g of a black mass of manganese dioxide as catalyst.
(2) Hydration reaction
A 3.5 g portion of the catalyst prepared in the aforementioned paragraph (1) was used to conduct the hydration reaction in the same manner as in Example 1 except that methyl ethyl ketone cyanohydrin was used in place of acetone cyanohydrin and methyl ethyl ketone was used in place of acetone.
As the result, the yields of 2-hydroxy-2-methylbutyric acid amide after 5 hours and 1 week were 85% and 88% respectively.
EXAMPLES 3
The same procedure was carried out as in Example 1 with the exception that lactonitrile was used in place of acetone cyanohydrin, and that raw material consisting of 20% by weight of lactonitrile and 80% by weight of water was passed through the reactor at a flow rate of 5.5 g/hr at a temperature of 50° C.
As the result, the yields of lactic acid amide after 5 hours and 1 week were 97% and 95%, respectively.
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A process for producing a denatured manganese dioxide for the hydration reaction of cyanohydrins comprising reacting an aqueous permanganate salt solution and an aqueous manganese (II) compound in an acidic aqueous solution at a temperature of 70° C. to 130° C. is disclosed. The manganese dioxide catalyst obtained by the process exhibits a high activity over a long period in the preparation of an amide by the hydration of the corresponding cyanohydrin.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of International Application No. PCT/FR2012/052614, filed on Nov. 13, 2012 which claims the benefit of FR 11/03562, filed on Nov. 23, 2011. The disclosures of the above applications are incorporated herein by reference.
FIELD
[0002] The present disclosure relates to a method for detecting the presence of bubbles and resin flow front during resin injection operations for manufacturing fiber composite parts.
BACKGROUND
[0003] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
[0004] The fiber composite parts comprise a network of fibers (carbon or glass, for example) embedded in a matrix of resin cured by heat polymerization.
[0005] The resin may be, for example, an organic resin (called organic matrix composite (OMC), epoxy resin, for example), a geopolymer resin, or a pre-ceramic resin.
[0006] Such parts are used in many industries, particularly in the aerospace industry, due to their excellent strength-to-weight ratio, and moderate manufacturing cost.
[0007] Among the various methods for manufacturing these fiber composite parts, are the injection type methods or LCM (liquid composite molding), and more particularly the RTM type (resin transfer molding) methods, consisting in injecting the resin under vacuum through the fiber tissues.
[0008] A common disadvantage related to these resin-injection-type methods is the appearance of air bubbles, resulting in competition between the capillary forces and the viscous forces.
[0009] The appearance of these bubbles causes the creation of vacuums in the final composite part which are likely to affect the strength and durability of this part.
[0010] Until now, the detection of these bubbles has been performed only at the end of the production line, through conventional non-destructive controls.
[0011] The disadvantage of such a posteriori detection is that it comes too late to allow for coercive actions to be carried out on the production line: when a very important bubble level is detected in a composite part thus produced, the only solution is to discard it.
[0012] This causes loss of time and materials which are very harmful to the overall economy of the process.
SUMMARY
[0013] The present disclosure provides a method for detecting bubbles during resin injection operations for manufacturing fiber composite components, by means of a facility comprising:
[0014] at least one mould and one counter-mould,
[0015] at least one pair of electrodes disposed respectively in this mould and this counter-mould,
[0016] a source of alternating current input voltage connected to one of these electrodes,
[0017] an RC circuit connected firstly to one of these electrodes and secondly to the mass, at the ends of which an alternating current reference voltage is found, and
[0018] means for signal processing, adapted to exploit the measurements of said alternating current input voltage and alternating current reference voltage,
[0019] wherein the rate of bubbles included between said electrodes is calculated based on said measurements.
[0020] This method permits to know the rate of bubbles in the resin of the composite through electrical measurements which can be performed in a very simple way.
[0021] According to other features of this method:
a relatively high frequency is used for said source of alternating current input voltage, the capacitance of at least one portion of the area formed by fibers and the liquid resin is measured, and said rate of bubbles is deduced from a relationship of the type φ v =f (ε v , ε r , ε f , and ε t , φ f , C cap ), where ε v , ε r , ε f , and ε t are respectively the permittivity constants of the vacuum, the resin, and the composite, and φ v , φ r , and φ f are respectively the rates of bubbles, resin and fibers between the two electrodes: the capacitance of this area is in fact influenced by the presence of bubbles, so that the measurement of this capacitance allows for immediate corrections (resin injection pressure, etc.) necessary for the disappearance of these bubbles; said capacitance measurement is used to derive the coefficients of depolarization of said bubbles, and thus the shapes and sizes of these bubbles; a relatively low frequency is used for said source of alternating current input voltage, said alternating current reference voltage is compared to a voltage value representing the theoretical value if the resin flowing between said electrodes was totally free of bubbles, and said rate of bubbles is deduced from the proportionality factor between these two values.
[0025] 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
[0026] In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:
[0027] FIG. 1 shows the electric diagram of the facility according to the present disclosure;
[0028] FIG. 2 shows two electrodes of the facility according to the present disclosure, with display of the edge effect parasitizing the measurements;
[0029] FIG. 3 shows the two electrodes of FIG. 2 , to which two guard electrodes were added in order to minimize the edge effects; and
[0030] FIG. 4 shows the variation of the modulus of the alternating current reference voltage overtime, as well as the variation of the modulus of a theoretical alternating current maximum voltage, corresponding to a complete absence of bubbles in the area on which the measurements are performed (note that the measurement is a voltage whether the sensor operates in capacitive or conductive mode).
[0031] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
DETAILED DESCRIPTION
[0032] 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.
[0033] In all these figures, identical or similar references refer to identical or similar members or groups of members.
[0034] Referring now to FIG. 1 , wherein two electrodes 1 and 3 are shown, intended to be integrated into the mould and counter-mould of an apparatus for manufacturing a part made of fiber composite by a liquid-resin-injection-type method (LCM method).
[0035] Such a method involves placing fiber fabrics, for example in carbon or in glass, between the mould and the counter-mould, and injecting a resin (epoxy, geopolymer, or pre-ceramic resin for example) in these fabrics: the resin impregnates the fiber fabrics by moving with a progression front.
[0036] When this front progression has cut across all fiber fabrics, the temperature may be raised so as to allow the resin to polymerize around the fibers.
[0037] As stated in the preamble of the present description, progression of the resin through the fibers is very often accompanied by the creation of air bubbles, which may subsequently generate porosity in the final part, which is not acceptable in terms of mechanical strength of the part.
[0038] The two electrodes 1 and 3 positioned on both sides of the area formed by the liquid resin and the fibers will make it possible to detect the presence of the bubbles before the resin polymerization step, as is clear from the following explanations.
[0039] An alternating current voltage V in (t) is applied to the electrode 1 and a reference voltage V ref (t) is measured on the other electrode 3 .
[0040] More specifically, the voltage V ref (t) is tapped off an RC-type circuit comprising a resistor R ref and a capacitor C ref , this circuit being interposed between the mass M and the electrode 3 .
[0041] The two electrodes 1 and 3 are separated by a distance substantially corresponding to the thickness of the part to be manufactured.
[0042] As can be seen in FIG. 1 , the area formed by the resin and the fibers can itself be modeled as an RC-type circuit having its own resistance R cap and its own capacitance C cap .
[0043] The method according to the present disclosure consists in measuring the capacitance C cap , which, we have come to realize, was indicative of the presence, quantity and shape of the air bubbles trapped in the resin.
[0044] Theoretical studies have shown that the presence, quantity, and shape of these air bubbles affect the permittivity of the area constituted by the resin and the fibers, and therefore the equivalent capacitance of the area.
[0045] More specifically, the complex impedances Zref (t) and Zcap (t) of the two RC circuits shown in FIG. 1 are determined as follows:
[0000] Z ref ( t )=1/( 1/R ref +1 ωC ref )
[0000] Z cap ( t )=1/(1/ R caps +1 ω C Cap )
[0046] We deduce from these relationships that when ω is “high” (i.e. the frequency of the alternating current voltage Vin (t) is very important):
[0047] C cap =C ref ·V ref /(V ref ) Sensor running on the capacitive model.
[0048] in such a way that knowledge of V in (t) and V ref (t) permits to find the equivalent capacitance C cap of the area formed by the fibers and the liquid resin: the sensor formed by the two electrodes 1 and 3 thus operates according to a capacitive mode.
[0049] In practice the steel moulds and the electronic environment of the sensor generate a parasitic capacitance which disturbs the measurement.
[0050] The C ref capacitance should thus be modified according to a law of the type:
[0000] C ref (modified)( t ) =C ref ( t ) +C parasite ( t )
[0051] This parasitic capacitance can be evaluated by filling the volume between the electrodes with a material whose capacitance is known, thus providing the evolution of C parasite according to the variation of capacitance between the electrodes.
[0052] The other possibility is to perform a simultaneous measurement on both sides of the electrode by rearranging the electrodes and the reference. The ratio of these two voltages permits to eliminate the parasitic capacitance.
[0053] The last possibility is to maintain the guard electrode at the same potential as the sensor allowing at the same time for the suppression of edge effects but also the suppression of external interferences.
[0054] Conversely, when working with low w values, we deduce from preceding relationships:
[0055] R cap =R ref. ((V in −V ref )/V ref ) Sensor running on the electrical conductivity model.
[0056] hence permitting to determine the equivalent resistance R cap of the area formed by the liquid resin and the fibers: the sensor formed by the electrodes 1 and 3 then runs on the electrical conductivity model (it may then be wise to remove the reference capacitance which is no longer useful).
[0057] Thus, when working at high frequencies and analyzing the voltage Vref (t), information regarding the presence, number and shape of the bubbles present in the liquid resin just prior to polymerization can be accessed.
[0058] Depending on the results of this information, we can correct a number of parameters of the process such as the resin injection pressure, so as to try to reduce the bubbles in the resin, and thus avoid ending up in fine with a polymerized part having an inacceptable porosity.
[0059] More specifically, the equipment for analyzing the voltage V ref (t) needs a signal processing equipment, which may comprise a signal conditioner, supplying an analog signal to a sample-and-hold circuit, which is in turn connected to an analog-to-digital converter.
[0060] The role of the sample-and-hold circuit is to collect instantaneous values and to maintain them at the input of the analog-to-digital converter during at least the time required for one conversion.
[0061] The sample-and-hold circuit and analog-to-digital converter can be controlled by a logic circuit which gives the order of sampling at the selected moments.
[0062] Such a logic function can be performed by a simple wired logic system or a microprocessor that provides the possibility to program the desired management.
[0063] The output of the analog-to-digital converter may be either processed by a computer (see the following regarding the rate of bubbles), or stored for later analysis, or even reconstituted in its original analog form by a digital-to-analog converter and used in controlling the process.
[0064] As shown in FIG. 2 , there are of course edge effects 5 , 7 , at the periphery of the two electrodes 1 and 3 , which might disrupt the reliability of the measurements.
[0065] This is why guard electrodes 9 , 11 and 13 , 15 , are added at the periphery of the two electrodes 1 and 3 , in such a way as to preserve the latter electrodes from edge effects, and thereby obtain reliable voltage measurements.
[0066] Results which are typically obtained with the previously described measuring device are shown in FIG. 4 .
[0067] The abscissa of the graph of FIG. 4 represents the time, and the ordinate of this graph represents the value of the measured voltage V ref (t).
[0068] The line F indicates the passage of the resin front to the right of the two electrodes 1 and 3 .
[0069] As this chart illustrates, therefore, the voltage V ref (t) rises sharply at the arrival of the resin front F, then continues to rise less significantly once this front is passed.
[0070] The dotted curve V max represents the theoretical value of V ref if the liquid resin flowing between the two electrodes 1 and 3 were completely devoid of bubbles: we see that in this hypothesis, the voltage V ref (t) would reach a strictly flat level shortly after the passage of the resin front.
[0071] A first manner of determining the rate of bubbles in the resin is to operate the device described above, according to the capacitive mode, that is to say with high frequencies for the alternating current voltage V in (t) applied to the electrode 1 .
[0072] By naming φ v , φ r , and φ f the rates of bubble, resin and fibers between the two electrodes 1 and 3 , we have the relationship φ v , +φ r , +φ f =1.
[0073] By naming ε v , ε r , ε f , and ε t respectively the permittivity constants of vacuum, the resin, the fibers and the composite, we obtain a relationship of the type, φ v =f(ε v , ε r , ε f , and ε t , φ f , C cap ), when the device operates in the capacitive mode.
[0074] We can hence deduce from this type of relationship the value of the rate of bubbles φ v .
[0075] Another way to determine this rate is to operate the measuring device described above in the resistive mode, that is to say with relatively low frequencies for the alternating current voltage V in (t).
[0076] In this particular mode of operation, it can be shown that there is a relationship of direct proportionality between the V max and V ref (t) values (see FIG. 4 ), the proportionality factor between these two values being representative of the liquid saturation S of the area disposed between the two electrodes 1 and 3 .
[0077] As a result, the vacuum rate (rate of bubbles) can be expressed as (1−S)*100.
[0078] Thereafter, when we want to push further investigations especially in relation to the shape of bubbles, we process appropriately the signal representative of the capacitance C cap of the area disposed between the two electrodes 1 and 3 .
[0079] This signal includes, in fact, information relating to the permittivity of the different components of the area (fiber, resin, vacuum), this permittivity being a function of the volume rate of each of these components and of their shape (more precisely, the arrangement of the surfaces in contact between the components in the measured volume).
[0080] We can then deduce, from these permittivity variations and from the constitutive equations of the area formed by the resin, fibers and bubbles, shape factors which are representative of the geometry (cylindrical or spherical) of the bubbles.
[0081] As can be understood in view of the foregoing description, the method and the installation according to the present disclosure permit, in a very simple manner, to measure a number factors such as the presence, the rate and the shape of the bubbles located inside the liquid resin which will infuse through the fiber fabrics, just before the polymerization step.
[0082] We can deduce from these measurements coercive actions to be carried out in order to limit, or even reduce, the risk of getting in fine a porous composite part.
[0083] These measurements also permit to detect the end of the resin filling, which manifests when there are no longer bubbles in the resin.
[0084] Only one pair of electrodes 1 , 3 has been shown in the context of the present description, but it must of course be understood that several pairs of electrodes can be arranged in several places of the mould and the counter-mould for making the composite part, in order to detect the presence of bubbles in different portions of the area formed by the liquid resin and the fibers.
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A method of detecting bubbles during operations for injecting resin for the manufacture of fibre composite components, is noteworthy in that the electrical capacitance or conductivity of at least one part of the medium formed by the fibres and the liquid is measured.
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BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for lubricating the inside walls of moulds for blanks, for example moulds for compacting powdered materials into blanks for sintered parts.
The technique of compacting powdered materials generally provides for the use of suitable presses equipped with at least one plunger, one mould or die and a device for pouring the powdered material to be compacted into the mould and commonly called a filling shoe.
By compressing the powder poured into the mould by means of the filling shoe with the plunger, there is obtained a compacted part or blank, technically called a "green" moulding, which is thereafter subjected to the sintering process.
During the stage of compaction of the powder, frictional resistances are manifested which cause the dissipation of part of the load applied by means of the plunger.
These frictional resistances comprise:
1. friction between plunger and mould;
2. friction between the grains of powder;
3. friction between the mass of powder and the walls of the mould.
While the frictional resistance which is manifested between the grains of the powder produces cold microwelds and therefore confers greater strength upon the blank, the frictional resistances between the plunger and the inside walls of the mould and between the mass of powder and the walls of the mould contribute only to dissipating part of the load applied by the plunger and therefore reduce the useful load applied to the powder.
DESCRIPTION OF THE PRIOR ART
One method for reducing the aforesaid losses of load provides for the prior mixing of the powder with lubricant, generally powdered zinc stearate. That is, the mould is filled with a mixture, in suitable percentages, of powder to be compacted and lubricating powder.
This kind of lubrication suffers a number of drawbacks. The presence of the lubricant within the compacted part prevents the formation of cold microwelds due to the frictional resistance between the particles of powder, thus prejudicing the strength of the green moulding. During the sintering there must also be provided a preliminary stage in which the zinc stearate is partially removed from the green moulding and this entails costly equipment and losses of time.
Methods are known for compacting powdered materials for parts to be sintered to obtain compact parts of high density greater than 7 kg/dm 2 , for example by means of electrodynamic units. The presence of lubricating powder mixed with the material to be compacted prevents the attainment of this high density in the compacted part. In effect, the presence of the lubricant within the compacted part creates interruptions in the metallic mass and this is prejudicial to the density attainable during the compaction, both through the removal of part of the lubricant with respect to the metallic mass. The lubricating powder has, for equal bulk, a specific gravity of the order of magnitude of 1/10th that of the metal powder and, therefore, the theoretical density obtainable is lower than the case in which there is no lubricating powder within the metal powder.
As an alternative, there is known a method of lubricating only the inside walls of the mould to reduce the frictional resistances between the plunger and the mould and between the metal powder and the mould. The method provides generally for the deposit of a film of lubricant on the inside walls of the mould by spraying the lubricant inside the mould itself before the charging of the powdered material to be compacted.
This method, although it obviates the problems deriving from the prior mixing of the lubricant and the powder to be compacted, is of limited application inasmuch as it is usable only with moulds which define a particularly simple moulding cavity. In any case, the injected lubricant is not deposited uniformly on the walls.
Since this method of lubricating the walls only of the mould does not ensure either good adhesion of the lubricant to the walls or uniform deposit of the lubricant thereon, it renders the use of the method of compaction described hazardous.
SUMMARY OF THE INVENTION
According to the present invention there is provided an apparatus for lubricating moulds for blanks, wherein the lubricant is injected inside the mould, comprising charging means for charging the lubricant electrically and means operative to maintain the mould at an electric potential such as to attract the lubricant and cause it to be deposited on the inside walls of the mould.
In comparison with the other arrangements which are known, the apparatus according to the invention ensures uniform deposition of the lubricating film even in the case of moulds of complex shape and having zones which are not accessible with conventional sprays, ensures good adhesion of the lubricant to the walls and therefore renders practicable the method of compacting by means of high-speed presses.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in more detail, by way of example, with reference to the accompanying drawings, wherein:
FIG. 1 is a diagram of an apparatus embodying the invention for lubricating moulds for blanks;
FIG. 2 is a partial perspective view of a detail of the apparatus wherein a distributor is mounted on the filling shoe of a compacting press;
FIG. 3 is a section of a high-speed press equipped with a filling shoe and a corresponding control device;
FIG. 4 is an axial section, taken in two planes at 90° to each other, of a reservoir forming part of the apparatus of FIG. 1;
FIG. 5 is a partial cross-section of the reservoir of FIG. 4;
FIG. 6 is an axial section of the corona charger of the apparatus of FIG. 1;
FIG. 7 is a section on the line VII--VII of FIG. 6;
FIG. 8 is an axial section of the lubricant distributor of the apparatus of FIG. 1; and
FIG. 9 is a section on the line IX--IX of FIG. 8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
According to the preferred embodiment of the invention, the lubricating apparatus (FIG. 1) includes a reservoir 10 in which the lubricant is mixed with dry air coming from the reservoir 37 through the pipe 38, and which provides for drying the lubricant and forming an air-lubricant mixture. This mixture is caused to pass through a flexible pipe 1 into a corona charger 40 which, fed by a d.c. power source 60 having one terminal earthed, charges the lubricating particles electrically, and then the mixture is introduced via a flexible pipe 2 into a distributor 65.
The distributor is mounted on a filling or feed shoe 100 of the press at the side of the feed duct for the powdered material. The distributor is provided with a needle valve which can adopt two positions:
in a first position it enables the air/lubricant mixture to pass through the distributor and reach, via a flexible pipe 3, a recycling blower 90 which re-introduces it into the reservoir 10 via a flexible pipe 4;
in a second position it enables the mixture to be sprayed inside the mould through nozzles.
The mould is electrically earthed and thus the electrically charged particles of lubricant come to adhere uniformly to its inside walls.
FIG. 2 shows how the distributor 65 is off-set on the filling shoe 100. The filling shoe 100 is mounted on a pivot 200 fixed to the structure 105 of the press and overhangs the mould-bearing surface 157 and the mould 151. The distributor 65 is off-set at the side of the terminal portion 101 containing the duct from which the powder to be compacted issues. At the beginning of each compacting cycle, the filling shoe 100 is rotated around the pivot 200, through the medium of a system of levers and cams hereinafter described, from the inoperative position of FIG. 2, bringing in sequence into a position overhanging the filling opening 149 of the mould, first the distributor 65 in order to carry out the lubrication of the inside walls of the mould, and then the terminal portion 101 in order to carry out the loading of the powder.
FIG. 3 is a median section of a high-speed press for compacting powdered material at high density, which is described in our U.S. Pat. No. 935,799 and shows the feed mechanism for the movement of the filling shoe.
The press 150 includes a mould consisting of two portions 151 and 152 and is adapted to compact a part or piece constituted by two generally prismatic parts 153 and 154 of different sections. The part 153 is compacted by the plunger 121 carried by a structure 122 comprising a coil 134 fixed to the structure 122, and a plate 135 of conducting material connected to a plate 136 to which the plunger 121 is fixed.
The part 154 is compacted by the plunger 169 carried by a structure 170 identical to the structure 122 previously described. The coils 134 are connected to a battery of capacitors. The mould portion 152 is fixed to a frusto-conical part 156 of the fixed frame of the press. The mould portion 151 in turn is carried by a plate 157 slidable vertically on the frame 105.
In FIG. 3 the filling shoe 100 is in the working position, in the stage in which the powder is poured into the mould. The filling shoe 100 is mounted on a pivot 200 mounted on the structure 105 through the medium of the bushes 201, 202. The pivot 200 has a projection 205 disposed at 90° with respect to the axis of the pivot itself and cooperating through the medium of a pin 206 with an arm 207 fixed to the lever 208 by means of a pin 211. The lever 208 is pivoted on a spindle 209 and is adapted to co-operate through the action of a spring 210 and through the medium of a roller 213 with a cam 212 pivoted on the shaft 133.
At the beginning of the cycle, the mould portions 151 and 152 are joined together and the filling shoe 100 is rotated by means of the cam 212 and the lever 208. The cam 212 has two steps 212a and 212b connected by a plane portion 212d. During the rotation of the cam 212, the roller 213 encounters the first step; this causes the lever 208 to shift so as to bring the distributor 65 (FIG. 2) into correspondence with the filling opening 149 (FIG. 2) to effect the lubrication of the inside walls of the mould.
The roller 213 then encounters the second step and this causes the lever 208 to shift alternately to bring the terminal portion 101 of the filling shoe 100 into correspondence with the filling opening to effect the loading of the powder. The roller then encounters the depression 212c, causing the filling shoe to return in this way to the inoperative state (FIG. 2).
The compacting cycle is then initiated as described in the above-mentioned Patent. Through the medium of the levers 128 and 173 the cams 132 and 177 shift the two structures 122 and 170 in opposite directions so as to effect the pre-compacting of the powder by means of the plungers 121 and 169.
Thereafter, the two depressions 144 and 110 of the cams 132 and 177 allow the springs 131 and 176 to move the structures 170 and 122 away from the mould portions 151 and 152 for a predetermined distance. Because of the pre-compaction, the part or piece has by this time a sufficient cohesion, so that the moving away of the lower plunger does not damage the part itself.
A discharge of the capacitors is now produced and this is delivered substantially simultaneously to the two coils 134 in a manner known per se. The coils 134 now cause a rapid movement of the plates 136 in opposite directions, as a result of which the two plungers 121 and 169 effect the final compacting of the part by acting thereon from opposite sides.
The cam 132 now allows the spring 131 to bring the structure 122 back upwardly and the structure is followed by the plunger 121, while the cam 168 moves the plate 157 upwardly together with the mould portion 151 through the medium of the lever 164, the plate 159 and the columns 158.
By means of the lever 173, the cam 177 now shifts the structure 170 further upwardly together with the lower plunger 169, the sleeve 183 and the plate 181, as a result of which the moulded part is brought into the space between the two mould portions 151 and 152 and can be discharged from the press. The cams 168, 177 now bring the upper mould portion 151 back into contact with the lower mould portion 152 and the lower plunger 169 back into the inoperative position.
The reservoir 10 (FIGS. 4 and 5) is constituted by a rigid external structure 11 supporting internally a cylindrical container 15 of insulating material, for example PTFE. A tube 17, also of PTFE, is suspended inside the container 15 by means of the lugs 16. The flexible pipe 4 reaches the interior of the container 15 in the proximity of the tube 17 through a hole 18 in the external structure 11 and a hole 19 in the container 15. Dry air coming from a reservoir 37 is introduced through the pipe 38 into the flexible pipe 4 (FIGS. 1 and 4), the dry air being maintained in the reservoir 37, through known means, at a pressure slightly higher than the outside pressure, for example 1.3 atmospheres. The pressure may be varied through known means. The rigid external structure 11 is supported by an external structure (not shown) through the medium of the brackets 20 co-operating with the flexible couplings 21.
The lubricating powder 22, for example zinc stearate, is located in the hollow space 25 between the cylindrical container 15 and the tube 17 and, in accordance with the natural tendency of heaps or masses of powdered materials, is disposed in the proximity of the pipe 4.
The reservoir 10 is closed hermetically at the top by a cover 26. In fact, a handwheel 28 can be screwed by means of a threaded hub 29 into the crosspiece 30 co-operating with two diametrically opposed brackets 32 rigidly connected to the structure 11 and presses the cover 26 against the external structure 11 and the cylindrical container 15 by means of the end of the hub. Two funnels 34 disposed in the hollow space 25 are connected to the pipe 1 through the hole 35 in the cover 26.
During the operation of the apparatus, the flexible pipe 4 introduces a jet of dry air mixed with the recycled air-lubricating powder mixture in the proximity of the tube 17; more lubricating powder disposed as described in the hollow space 25 is entrained inside the tube 17.
The cover 26 is shaped internally so as to cause the mixture of air and powder issuing from the tube 17 to drop back close to the mouths 36 of the funnels 34, which are then able to suck up the aforesaid mixture. A vibrating device 39 of any type causes the reservoir 10 to vibrate continuously in a diametral direction, preventing the powder becoming packed in the hollow space 25.
The air-powder mixture is introduced through the flexible pipe 1 into the corona charger. The corona charger 40 (FIGS. 6 and 7) comprises an outer frame 42 of insulating material, for example PTFE, having an internal cavity in which is accommodated a container 45 of insulating material, for example PTFE, provided with two passages 46 and 47 of circular cross-section. In the container 45 there is arranged an electrode 50 constituted by a hollow cylinder 51 housed in the passage 47 and a flange 52 of conducting material accommodated between the container 45 and the outer frame 42. The frame 42 is provided with a hollow extension 43 connecting one opening of the hollow cylinder 51 with the flexible pipe 2. The container 45 is provided with a hollow extension 48 which connects the other opening of the hollow cylinder 51 with the flexible pipe 1.
An electric conductor 55 insulated by a sheath 56 is housed in the passage 46 and is in contact with the flange 52. The conductor 55 is supplied by a suitable source 60 (FIG. 1) of d.c. power of a value, for example of 50 kV, and having one terminal earthed.
At the inlet edges 57 and outlet edges 58 of the hollow cylinder 51 a strong ionization of the air is obtained; the ions produced bombard the particles of lubricant in suspension in the air and charge them electrically. The electrically charged air-lubricating powder mixture reaches the distributor 65. The distributor 65 (FIGS. 8 and 9) comprises a needle valve 68, the stem 69 of which is integral via a flange 70 with a cylindrical body 71 which constitutes the armature of an electromagnet 74 and is shifted to the right (FIG. 8) when the electromagnet 74 is energised.
The electromagnet is housed in a cylindrical structure 75 which is provided with an internal shoulder 77. A spring 78 connects the flange 70 with the shoulder 77, urging the stem 69 to the left. The structure 75 is housed in an outer casing 80.
The valve 81 has an inner chamber 82 of cylindrical form closed towards the electromagnet by a gasket 83 fixed between the inner structure 75 and the outer casing 80. The inner chamber 82 communicates with a duct 84 for bringing up the air and lubricant mixture and with a duct 85 for the recycling of the mixture through the flexible pipe 3 when the needle valve is closed. The inner chamber 82 is in communication, through an internal groove 86 formed in the casing 80, with another duct 87 which supplies two nozzles 88 adapted to inject the air and lubricant mixture when the needle valve is open. In fact, the mixture of dry air and lubricant is maintained within the circuit at a pressure higher than atmospheric pressure. The unused mixture of air and lubricant is sucked through the duct 85 and the flexible pipe 3 (FIG. 1) by the recycling blower 90 of centrifugal type, which provides for the delivery thereof back to the reservoir 10 through the flexible pipe 4, thus renewing the cycle. The head of the blower is, for example, 0.03 atmosphere. The lubricating powder mixture is kept always in circulation. The head of the blower may be varied by known means, therefore varying the recycling velocity of the mixture of air and lubricant until the latter is prevented from blocking the pipes.
The electromagnet 74 is energised by square waves through the line 97 leading from the generator 96 (FIG. 3), which is enabled by a proximity sensor 95.
The proximity sensor 95 is positioned opposite the circumference 206 described by the end 215 of the lever 214 fixed to the shaft 133 and is triggered when the end 215 is in the position of minimum distance.
The position of the lever 214 of the shaft is synchronised with the position of the cam 212 so that when the end 215 is located in the position of minimum distance from the proximity sensor 95 the roller 213 is located at the beginning of the plane portion 212d, that is at the same moment when the distributor is positioned above the loading opening 149 of the mould by the filling shoe. The proximity sensor 95 enables the generator 96 to emit a square wave. The duration of the square wave characterises the time of opening of the valve, and therefore by regulating the amplitude of the square wave it is possible to vary the quantity of lubricant injected. The quantity of lubricant injected may also be varied by varying the pressure of the dry air in the reservoir 37 (FIG. 1). In this way, it is possible to adjust the quantity of lubricant injected as a function of the shape and size of the compacting mould used.
As long as the electromagnet 74 is de-energised, the stem 69 urged by the spring 78 prevents the air-lubricant mixture coming from the duct 84 supplying the duct 87 and, therefore, the nozzles 88. The mixture coming from the duct 84 returns through the duct 85 and the flexible pipe 3 to the aspirator 90 to be recycled afresh.
When the distributor 65 is positioned above the loading opening of the mould, the electromagnet 74 is fed by a square wave, the cylindrical body 71 is attracted to the right and the duct 84 is thus placed in communication with the duct 87. The air-powder mixture can be injected inside the mould through the nozzles 88. The lubricant particles charged, for example, positively are attracted by the mould, which is electrically earthed, for example, and therefore covers the inside walls of the mould with a uniform film whatever shape they may have.
In the apparatus embodying the invention the air and lubricant mixture is recycled continuously, thus permitting prompt delivery of the mixture to the nozzles when required.
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An apparatus for lubricating the internal wall of moulds for blanks comprises a corona charger for charging electrically the lubricant which is then injected into the mould. This latter is maintained at an electric potential such as to attract the lubricant and cause it to be deposited on the inside walls of the mould.
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This application is a continuation of application Ser. No. 195,826, filed Oct. 10, 1980, which in turn is a continuation of Ser. No. 811,704, filed June 30, 1977, both now abandoned.
BACKGROUND
Laser beam and electron beams have been used to produce fusion reactions involving heavy isotopes of hydrogen. This method suffers from a number of drawbacks which the method using ion beams seeks to obviate. Among these disadvantages are: the beams of the prior art do fail to carry energetic nuclear reactants in to the reaction zone; the nuclear reaction rely on thermal heating rather than on an accelerated ion beam reaction mechanism; the prior art experiences severe difficulties in the attempts to correlate the acceleration, focusing, synchronizing of all beams. The apparatus and the method of the present invention seek to overcome the above listed drawbacks of prior art.
SUMMARY
The nuclear fusion device of the present invention makes use of a condensed state fuel element which is subjected to accelerated and pulsed ion beams which comprise one of the nuclear reactants. For example the following reactants may be employed. Protons and deuterons and electrons are employed for the ion beams. The proton deuteron and electron beams are focused on condensed phase fuels comprising in a preferred embodiment heavy isotopes of hydrogen (deuterium and tritium) the isotopes of lithium, berylium and boron. The preferred reactions for the process of this invention are ##STR1## since these two reactions are nuclearly clean and produce only Helium and no radiactive elements. The condensed state fuels may be presented in elemental form or in the form of chemical compounds.
Isotopes of hydrogen may be employed in liquid form or in the form of hydrides and other suitable compounds formed between the light elements and hydrogen. Lithium, berylium and boron are solids which can be made into wire, filament or tape in a continuous endless form. Further, these elements conduct electricity and are utilized in an embodiment of this invention as the component of a beam accelerating, focusing, and synchronizing system. The condensed state fuels may also be presented as a liquid in a jet form, in pellets mounted on a carrier, or on portions of liquid carried in a hollow filament. The solid fuels may be presented in a continuously formed or extruded slender body comprising substances including metals, their alloys and suitable organic and inorganic substances including polymers. The said nuclear fusion device may also be employed as a neutron source. The following reactions used for neutron generation are given in Table I.
Examples of nuclear reactions suitable for the nuclear fusion device of the present invention are listed also in Table I.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1a is a top crossectional view of a fusion reaction chamber comprising a centrally mounted condensed state nuclear fusion fuel element surrounded by ion source stations whose output ion beams are accelerated, focused and synchronized by a set of concentric elements comprising accelerating electrodes forming channels that direct the said beams of ions on the said centrally mounted fuel element.
FIG. 1b is a side crossectional view of the fusion reaction chamber showing two ion sources and two opposed pairs of accelerating and focusing electrodes forming and guiding the ion beams onto the fuel element in the center.
FIG. 2 is a block diagram showing fuel and waste flow, linear element forming stations and, reaction chamber and the electrical energy generating station.
FIG. 3 is a transverse representation showing two ion beams focused on the linear condensed state fuel element.
FIG. 4 is a schematic representation in three dimensional perspective of six beams focused simultaneously on a condensed state nuclear fuel element.
FIGS. 5a to h are representations of various forms of the condensed state linear fuel elements.
FIGS. 6a to c are transverse crossectional representation of ion source electrode for the generation of ions derived from the isotopes of hydrogen.
DESCRIPTION
In FIG. 1a is the view from the central crosssection of the fusion reaction chamber.
FIG. 1b represents the side view of the same chamber. The fusion reaction chamber can be cylindrical or spherical. The chamber consists of concentric cylinders 2, 3, 4, 5, 6, 7, 8 or more than that, or of conspheric spheres 2, 3, 4, 5, 6, 7, 8 or more. These cylinders or spheres are made of conducting material. In these spheres are built focusing and accelerating electrodes 10, 11, 12, 13, 14, 15, 16 or more. These electrodes are placed on radial direction as shown in FIG. 1a. The sources of protons 1 is placed at the entrance of the electrodes. The material for the nuclear fusion reaction is placed at the center and is numbered 9. It can be any light element, preferably not producing neutrons. Each time an accelerating pulse is applied on the focusing and accelerating electrodes 10, 11, 12, 13, 14, 15, 16 or more a reaction of fusion occurs at 9, and the next pulse the electrode 9 is renewed by feeding system activated from outside. The reaction products are collected on the outside electrode 18 or more. The essential property is the fact that the accelerating pulse on all electrodes is absolutely synchronous. The fusion raction chamber is in vacuum.
The block diagram of FIG. 2 depicts schematically the movement the nuclear fusion fuels and the extraction of electrical energy in the continuous process of the present invention. 22 is the storage of the condensed state nuclear fusion fuel which may be solid or liquid. This fuel may be comprised for example of isotopes, hydrogen, lithium, berylium and boron. These elements may be present in elemental form or in combined form with other elements. Isotopes of hydrogen may be introduced as a fluid jet. Metals such as lithium and berylium can enter the nuclear reaction chamber in form of a wire or a thin ribbon. Elemental boron may be introduced as a filament or a ribbon. These and other means of introducing fuel elements into the reaction chamber are further described in connection with FIGS. 5a to i. The fuel is transported through channel 30 to the forming station 24 where it is transformed into a continuous linear body. Station 24 may for example be a wire forming station or a continuous extruder producing a slender linear element such as a thin ribbon, a filament and the like. FIG. 25 represents a structuring station introducing for example a transverse structural modification or attaching fuel elements to a linear carrier formed previously in station 25. The linear element is than transported by means forwarding and guiding rolls 29' and 29" into the nuclear fusion reaction chamber 26 where it is reacted with intense ion beams comprising protons, deuterons or tritons which are transported by a path 29 from the storage station 21 in the direction shown by arrow R 3 . The energy produced by the nuclear fusion reaction is converted into electricity in the power plant 28 and the reaction products are passed by a transporting path 27 into the storage station 23.
FIG. 3 is a crossectional schematic representation of a part of the reaction chamber 26. The linear element 9 is fed from the applicator 36 into the reaction zone 38 where it is subject to two opposed ionized particle beams 32 and 34 produced by ion generating stations 31 and 33 and focused by electric or magnetic lenses 35 and 37. The two beams are focused on the same locus 39 of the linear element 9 and are synchronized in time so as to be pulsed, focused and applied simultaneously. Of the two said beams 32 and 34 each may comprise the same ions or different ions or one may be composed of ions the other beam may comprise electrons. Mixtures of ions in a single ion beam may also be employed. Ion generating stations are well known in the art but produce a disappointingly small number of ions per pulse. A special ion source is described in connection with FIGS. 6a to 6c'.
A multiplicity of beams may be employed all synchronized and focused on a single target focus of the fuel elements. FIG. 4 is a schematic representation of fuel element 9 receiving synchronized and focused beam pulses 42, 42', 43, 43' and 45, 45' approaching the fuel element 9 along the cartesion coordinates x, y and z of which x and y are in the plane 40 and Z is perpendicular to the said plane. The nuclear fuel element 9 may constitute a filament or wire 50 having a diamenter 49 (the element 50 may also represent a thin stream of liquid fuel 9) or a ribbon 52 of a width 53 and thickness 51 as shown in FIGS. 5a and 5b respectively. Alternatively fuel elements 9 may be mounted on carrier means as is shown in FIGS. 5c to 5i. Such a mounting of small fuel elements on a carrier is an advance over prior art where unsupported pellets have been employed in the area of laser fusion. The carrier mounted fuel elements provide for (1) exact positioning of the fuel element 9 (2) synchronization of the beam pulses and focusing a feat that would be hard to duplicate with an unsupported fuel element and (3) introduction of electricity into the reaction region by using an electrically conductive material for the linear element whether it comprises nuclear fusion fuel itself or acts as a carrier. Fuel elements are mounted on carriers in the following manner: Fuel elements 9 on a wire or filaments 50 (FIG. 5c); Fuel elements 9 on a ribbon or tape 52 (FIG. 5d); Fuel elements 9 in a hollow filament 54 having a lumen 55 and a wall 57 (FIG. 5e)--The fuel element 9 may be solid or liquid; two parallel wires or filaments 50 and 50' connected by a wavy filament 59 which carries fuel elements 9 mounted in between the two parallel filaments 50 and 51' (FIG. 5f); Filament and wire 50 attached to short wire or fibers 59 which are periodically mounted and carrying fuel elements 9 on their free ends (FIG. 5g); A ribbon 52 carrying a fuel strip 9 (FIG. 5h); and a pair of parallel filaments or wires connected with transverse wire or filament bridges 59" on which the fuel elements 9 are mounted (FIG. 5i).
A solid state ion source for emitting positive hydrogen ions is described in FIGS. 6a to 6c'. This electrode may emit protons, deuterons and tritons. In FIG. 6a and 6a' the electrode is shown tipped with a sponge 62; in FIG. 6b and 6b' it is shown tipped with whiskers or wires 64 which may also be in the inside chamber 63 where the wires are given the numeral 61. Razor blade edges 65 tip the ion source in FIGS. 6c and 6c'. The razor blade edges may also be placed inside of the ion source chamber cavity 63 where they are assigned the numeral 67. The wall 66 of the chamber 60 is permeable to hydrogen and is kept at high positive potential respect to the extractor electrode 70 and with respect to ground. The wall 66 of the ion source 60 and elements 62, 64, 61, 65, 67 are preferentially palladium but could be made of a variety of metals comprising transition metals and their alloys including platinum, and iron. The wall 66 of the ion source 60 may be heated to increase the mobility of the hydrogen through it. The chamber 63 of the ion source 60 contains hydrogen, deuterium or tritium gas under pressure. In an embodiment of the invention the ion source 60 comprises an electrolytic cell having as one electrode the wall 66, of the ion source 60 and another electrode 69. The chamber 63 contains a suitable hydrogen containing electrolyte and the two said electrodes are maintained at a proper electrolysis potential, the hydrogen deposited at the electrode wall 66 of the ion source 60 is stripped to the positive hydrogen ion by maintaining a high positive potential on the wall 66 with respect to the extractor and accelerator 70 and ground. In this manner a powerful ion source for protons, deuterons and tritons is obtained. For example molten lithium hydride serves as the electrolyte. By means of a suitable potential electrode 69 is made a cathode and the wall 66 of the ion source is made the anode. Lithium metal deposits on electrode element 69 and the hydrogen which enters the electrode wall 66 (which is biased strongly positive, as described above) is stripped to protons and extracted by the extractor electrode 70. In this manner deuterons and tritons are also obtained. The ion source 60 produces ions also with a smooth outside wall 66, but the emmission is enhanced by an increase in surfaces of the wall 66 and by the addition of sharp points or edges to the surfaces of the said wall. Among electrolytes suitable for depositing hydrogen on and into a palladium electrode are salts and acids containing acidic hydrogens, metal hydroxides and metal hydrides. The electrolyte mepdium can be anhydrous, aqueous and can use organic and inorganic solvents. Superheated steam below and above the critical region may be used as a medium.
Among the nuclides comprising at least in part the material of the condensed state nuclear fusion fuel and/or the material of the carrier of the said fuel elements are those which constitute at least in part the first three horizontal rows of the periodic table of elements.
The preferred parameters for the said nuclear fusion reactions fall into the following ranges:
(One) Crossection (diameter or thickness) of the nuclear fusion fuel elements serving as the target for the ion beam: microns to milimeters.
(Two) Energy of the ions in the beam: 10 kev to 5 MeV.
(Three) Energy content of a pulse or of a pulse set: 1 kilojoule to 10 megajoules.
(Four) Pulse duration: 1 nanosecond to several miliseconds.
TABLE I______________________________________Examples of Exothermic Nuclear ReactionsSuitable for the Nuclear Fusion Device CSIB______________________________________"Clean" Reactions ##STR2## ##STR3##Neutron Producing Reactions ##STR4## ##STR5## ##STR6## ##STR7##______________________________________
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A nuclear fusion device comprising a condensed phase fuel element and accelerated ion beams which ionize and compress the fuel element and initiate nuclear fusion reactions. In one of the embodiment beams comprising electrons in addition to ions are employed. A method is provided comprising synchronization, acceleration and focusing of the said beams on the fuel target. Another object of the invention is to provide an apparatus and method for a continuous nuclear fusion process. Another object is a clean fusion process. A further object of the invention is to provide a neutron generator.
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FIELD OF THE INVENTION
This invention relates to fabrication processes for semiconductor devices.
BACKGROUND
Microelectromechanical systems (MEMS), for example, gyroscopes, resonators and accelerometers, utilize micromachining techniques (i.e., lithographic and other precision fabrication techniques) to reduce mechanical components to a scale that is generally comparable to microelectronics. MEMS typically include a mechanical structure fabricated from or on, for example, a silicon substrate using micromachining techniques.
The mechanical structures in MEMS devices are typically sealed in a chamber. The delicate mechanical structure may be sealed in, for example, a hermetically sealed metal container (for example, a TO-8 “can” as described in U.S. Pat. No. 6,307,815) or bonded to a semiconductor or glass-like substrate having a chamber to house, accommodate or cover the mechanical structure (see, for example, U.S. Pat. Nos. 6,146,917; 6,352,935; 6,477,901; and 6,507,082). In the context of the hermetically sealed metal container, the substrate on, or in which, the mechanical structure resides may be disposed in and affixed to the metal container. The hermetically sealed metal container also serves as a primary package as well.
In the context of the semiconductor or glass-like substrate packaging technique, the substrate of the mechanical structure may be bonded to another substrate whereby the bonded substrates form a chamber within which the mechanical structure resides. In this way, the operating environment of the mechanical structure may be controlled and the structure itself protected from, for example, inadvertent contact. The two bonded substrates may or may not be the primary package for the MEMS as well.
The sensitivity of a particular device is a function of the spacing between the electrodes in a device and the device element. A typical gap between the electrode and the device element may be on the order of 1 micron to 10 microns. Provision of a small gap is desired to increase the performance capability of the device. By way of example, the sensitivity of a particular device is proportional to 1/d 2 wherein d is the width of the gap. Additionally, the power and voltage requirements for electrostatic actuation of the device are proportional to d 2 .
What is needed is a method of forming wafers such that the electrode spacing can be accurately determined. A further need exists for such a method which does not significantly increase the cost of producing the wafer. Yet another need exists for such a method which improves the antistiction performance of the device.
SUMMARY
In accordance with one embodiment of the present invention, there is provided a method of forming a device with a controlled electrode gap width including providing a substrate, forming a functional layer on top of a surface of the substrate, forming a sacrificial layer above the functional layer, exposing a first portion of the functional layer through the sacrificial layer, forming a first spacer layer on the exposed first portion of the functional layer, forming an encapsulation layer above the first spacer layer, and vapor etching the encapsulated first spacer layer to form a first gap between the functional layer and the encapsulation layer.
In accordance with a further embodiment, a method of forming a device with a z-axis electrode includes providing a substrate, forming a functional layer on top of a surface of the substrate, forming a sacrificial layer above the functional layer, etching a first electrode hole in the sacrificial layer, forming a first spacer layer within the first electrode hole, forming a first encapsulation layer portion above the sacrificial layer and above the first spacer layer, and removing the encapsulated first spacer layer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a side cross-sectional view of a wafer device with a gap between a Z-axis electrode and a resonator in accordance with principles of the present invention;
FIG. 2 depicts a flow chart of a process for manufacturing a device with a gap between a Z-axis electrode and a resonator in accordance with principles of the present invention;
FIG. 3 depicts a cross-sectional view of a substrate, which in this embodiment is a silicon on insulator (SOI) substrate, with a photomask, which may be used in a device in accordance with principles of the present invention;
FIG. 4 depicts a cross-sectional view of the substrate of FIG. 3 with trenches formed in the functional layer of the substrate;
FIG. 5 depicts a cross-sectional view of the substrate of FIG. 4 with the trenches sealed with a sacrificial layer and holes for defining an electrical contact and an electrode formed in the sacrificial layer;
FIG. 6 depicts a cross-sectional view of the substrate of FIG. 5 with a spacer layer formed on a portion of the functional layer which was exposed through the sacrificial layer;
FIG. 7 depicts a cross-sectional view of the substrate of FIG. 6 with a thin portion of an encapsulating layer formed over the sacrificial layer and the spacer layer;
FIG. 8 depicts a cross-sectional view of the substrate of FIG. 7 with vent holes formed in the thin portion of the encapsulation layer;
FIG. 9 depicts a cross-sectional view of the substrate of FIG. 8 after vapor etching has been used to define the electrical contact, to provide a gap between the electrode and the resonator structure, and to release the resonator structure;
FIG. 10 depicts a cross-sectional view of the substrate of FIG. 9 after the remaining portion of the encapsulation layer has been formed and vent holes have been etched through the encapsulation layer;
FIG. 11 depicts a cross-sectional view of the substrate of FIG. 10 with an oxide layer defining an electrical contact hole formed above the encapsulating layer; and
FIG. 12 depicts a cross-sectional view of the substrate of FIG. 11 with an electrical contact formed in the electrical contact hole of the oxide layer.
DESCRIPTION
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification. It is understood that no limitation to the scope of the invention is thereby intended. It is further understood that the present invention includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the invention as would normally occur to one skilled in the art to which this invention pertains.
FIG. 1 depicts a side cross-sectional view of a wafer device 100 . The wafer device 100 includes a substrate 102 , which, in this embodiment, is a silicon on insulator (SOI) substrate. The substrate 102 includes an SOI handle layer 104 , a buried oxide layer 106 and an SOI functional layer 108 . A sacrificial oxide layer 110 is located above the functional layer 108 followed by an epitaxial encapsulation layer 112 and an oxide layer 114 .
A chamber 116 extends from the sacrificial oxide layer 110 through the functional layer 108 and into the buried oxide layer 106 . A resonator 118 is located within the chamber 116 and is formed in the functional layer 108 . A Z-axis electrode 120 is located above the resonator 118 and separated from the resonator 118 by a gap 122 . Trenches 124 extend through the encapsulation layer 112 to electrically isolate the Z-axis electrode 120 and trenches 126 extend through the encapsulation layer 112 to electrically isolate an electrical contact 128 which extends through the oxide layer 114 .
FIG. 2 shows a flow chart 150 of a manufacturing process that may be used to produce the wafer device 100 . The process 150 of FIG. 2 begins (block 152 ) and a substrate is provided (block 154 ). A photomask defining a resonator structure is then used to form the resonator structure (block 156 ). Once formed, the resonator structures are sealed with a sacrificial oxide layer (block 158 ). Electrical contacts and electrode contacts are then etched into the seal layer (block 160 ). A spacer layer is formed on the electrode contact (block 162 ) and a first portion of an encapsulation layer, which in this embodiment is a thin silicon layer, is formed over the seal layer (block 164 ). Vent holes are etched through the thin silicon layer (block 166 ) and a vapor phase hydrofluoric acid (HF) is used to etch the sacrificial oxide layer to release the resonator structure (block 168 ). The vapor phase etch further etches the spacer layer to provide a gap between the electrode structure and the resonator (block 170 ).
The second portion of the encapsulation layer is formed (block 172 ) which closes the vents and provides structural stability, and the top surface of the encapsulation layer is planarized using chemical mechanical polishing (CMP) (block 174 ). The planarized surface is etched to provide trenches which define isolated pillars of silicon for electrical throughputs (block 176 ). An oxide layer, deposited on the wafer to close the trenches (block 178 ), is etched to define electrical contacts (block 180 ) and the electrical contact is then formed (block 182 ). The process then ends (block 184 ).
One example of the process of FIG. 2 is shown in FIGS. 3-12 . A substrate 200 is shown in FIG. 3 . The substrate 200 in this embodiment is a silicon on insulator (SOI) substrate including an SOI handle layer 202 , a buried silicon dioxide layer 204 and a functional SOI layer 206 . A photomask 208 is formed on the exposed upper surface of the SOI active layer 206 . Deep reactive ion etching (DRIE) of the substrate 200 creates trenches 210 which define an unreleased resonator in the functional SOI layer 206 . Next, a sacrificial layer 212 of LPCVD oxide is used to seal the trenches 210 and an electrical contact hole 214 and a Z-axis electrode hole 216 are etched into the sacrificial layer 212 as shown in FIG. 5 .
A spacer layer 218 is then formed in the Z-axis electrode hole 216 ( FIG. 6 ) and a first portion 220 of a silicon encapsulation layer is deposited on the sacrificial layer 212 . In one embodiment, the first portion 220 is about 2 microns in depth. Vent holes 222 and vent holes 224 are etched through the first portion 220 as shown in FIG. 8 . Vapor-phase HF is used to etch the sacrificial layer 212 located adjacent to the vent holes 222 and 224 . Etching of the sacrificial layer 212 adjacent to the vent holes 222 defines an electrical contact 226 in the first portion 220 . Etching of the sacrificial layer 212 adjacent to the vent holes 224 exposes some of the trenches 210 allowing the etch vapor to contact and etch the buried silicon dioxide layer 204 , thereby forming a chamber 228 and to release the resonator structure 230 as shown in FIG. 9 . The vapor-phase HF further etches the spacer layer 218 creating a gap 232 between the Z-axis electrode 234 and the resonator 230 .
A second portion 236 of the silicon encapsulation layer 238 is deposited on top of the first portion 220 and vent holes 240 and 242 are etched through the encapsulation layer 238 (see FIG. 10 ). The vent holes 240 electrically isolate the electrical contact 226 and the vent holes 242 electrically isolate the Z-axis electrode 234 . The vent holes 242 also expose the chamber 228 to the environment above the encapsulation layer 238 . Accordingly, the environment above the encapsulation layer 238 may be modified to result in a desired pressure within the chamber 228 .
The vent holes 240 and 242 are then closed with an oxide layer 244 and an electrical contact hole 246 is etched through the oxide layer 244 (see FIG. 11 ). As shown in FIG. 12 , an electrical contact 248 , which in one embodiment is formed from aluminum, is formed in the electrical contact hole 246 .
The processes and devices described above may be modified in a number of ways to provide devices for different applications including, but not limited to inertial sensing, shear stress sensing, in-plane force sensing, etc. By way of example, additional chambers may be provided on a single substrate 200 . By selective deposition of one or more spacer layers, gaps of different widths may be realized between electrodes and resonators in the chambers to provide structures of different sensitivity within a wafer. Additionally, the thickness of the encapsulation lay may be selectively increased (decreased) over the entire wafer or over particular electrodes to provide stiffer structures.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same should be considered as illustrative and not restrictive in character. It is understood that only the preferred embodiments have been presented and that all changes, modifications and further applications that come within the spirit of the invention are desired to be protected.
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A method of forming a device with a controlled electrode gap width includes providing a substrate, forming a functional layer on top of a surface of the substrate, forming a sacrificial layer above the functional layer, exposing a first portion of the functional layer through the sacrificial layer, forming a first spacer layer on the exposed first portion of the functional layer, forming an encapsulation layer above the first spacer layer, and vapor etching the encapsulated first spacer layer to form a first gap between the functional layer and the encapsulation layer.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 13/211,081 filed on Aug. 16, 2011, which is a continuation of U.S. patent application Ser. No. 12/056,439 filed on Mar. 27, 2008, now U.S. Pat. No. 8,001,883, which claims priority to U.S. Provisional Patent Application Ser. No. 60/909,625 filed on Apr. 2, 2007. All of these prior applications are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
This invention relates to an improved design of a return to neutral mechanism 10 for use in a variable displacement hydraulic unit such as a pump, a hydrostatic transmission (“HST”) or an integrated hydrostatic transmission (“IHT”) incorporating output gearing and axles, and such devices can be used in a wide variety of uses, including vehicles and industrial applications. The operation of a hydrostatic application such as a pump, HST or IHT is generally known in the art and will not be described in detail herein. For example, the arrangement of an IHT and the operation of the components thereof are generally described in U.S. Pat. Nos. 5,314,387 and 6,122,996, the terms of which are incorporated herein by reference.
In general, an HST has a hydraulic pump and a hydraulic motor mounted in a housing. The pump and motor are hydraulically linked through a generally closed circuit, and both consist of a rotatable body with pistons mounted therein. Hydraulic fluid such as oil is maintained in the closed circuit, and the HST generally has a sump or reservoir with which the closed circuit can exchange oil. This sump may be formed by the housing itself.
In a typical arrangement, the pump is usually driven by an external motive source such as pulleys or belts connected to an internal combustion engine. The axial pistons of the pump engage a moveable swash plate and, as the pump is rotated by an input source driven by the external engine, the pistons engage the swash plate. Movement of the pump pistons creates movement of the hydraulic fluid from the pump to the motor to drive the motor cylinder block and the motor output shaft. This output shaft may be linked to mechanical gearing and output axles, which may be internal to the HST housing, as in an IHT, or external thereto. The swash plate is generally controlled by a control arm which is connected via linkage to either a hand control or foot pedal mechanism to control direction and speed.
The pump system is fully reversible in a standard HST. As the pump swash plate is moved, the rotational direction of the motor can be changed. The HST closed circuit has two sides, namely a high pressure side in which oil is being pumped from the pump to the motor, and a low pressure or vacuum side, in which oil is being returned from the motor to the pump. When the swash plate angle is reversed, the flow out of the pump reverses so that the high pressure side of the circuit becomes the vacuum side and vice versa. This hydraulic circuit can be formed as porting formed within the HST housing, or internal to a center section on which the pump and motor are rotatably mounted, or in other ways known in the art. Check valves are often used to draw hydraulic fluid into the low pressure side to make up for fluid lost due to leakage, for example.
A hydraulic pump will also have a “neutral” position where the pump pistons are not moved in an axial direction, so that rotation of the pump cylinder block does not create any movement of the hydraulic fluid. The swash plate is in neutral when it is generally perpendicular with respect to the pump pistons.
For safety reasons, and for the convenience of the user, it is preferred to have a return to neutral, or zero displacement, feature which forces the swash plate to its neutral position when no force is being applied to the control arm. Such a feature eliminates unintended movement of the vehicle, and returns the unit to neutral in the event of an accident where the vehicle operator is unable to physically disengage the transmission.
SUMMARY OF THE INVENTION
The invention provides an improved return design for a swash plate used with a variable displacement hydraulic pump, and in particular a simplified internal return to neutral design that uses fewer parts and is easier to install than known designs. This return to neutral design may either be bi-directional, returning the unit to neutral when stroked in either the forward or reverse direction, or uni-directional, providing a return force in only one direction and not the other. The invention is described herein in connection with a hydrostatic transaxle but it could be used in a device having only a pump without the separate hydraulic motor, or with the motor in a separate housing.
A better understanding of the objects, advantages, features, properties and relationships of the invention will be obtained from the following detailed description and accompanying drawings which set forth an illustrative embodiment and is indicative of the various ways in which the principles of the invention may be employed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the return to neutral feature of one embodiment of the present invention and an exemplary swash plate, showing the relationship of the two when the swash plate is in a stroked position.
FIG. 2 is an end view of the return to neutral feature and swash plate as shown in FIG. 1 , in conjunction with an exemplary center section, with the swash plate in the stroked position.
FIG. 3 is a view similar to that of FIG. 2 , with the swash plate in the neutral position.
FIG. 4 is a perspective view of an exemplary hydrostatic transmission encompassing a second embodiment of this invention.
FIG. 5 is a side elevational view of a swash plate and return to neutral mechanism in accordance with the second embodiment of this invention, with the swash plate in the neutral position.
FIG. 6 is a view similar to FIG. 5 , with the swash plate in a first stroked position.
FIG. 7 is a view similar to FIGS. 5 and 6 , with the swash plate in a second stroked position.
FIG. 8 is an opposite side elevational view of the swash plate and return to neutral mechanism as shown in FIG. 5 , and depicting a portion of the housing.
FIG. 9 is a partially cross-sectional side view of a portion of the housing and the return to neutral mechanism along the lines 9 - 9 as shown in FIG. 8 , where the adjustment mechanism is not cross-sectioned for clarity.
FIG. 10 is a plan view of the adjustment mechanism shown in FIG. 9 .
FIG. 11 is a perspective view of the second embodiment of this invention, depicting the return to neutral structure and exemplary swash plate, showing the relationship of the two when the swash plate is in a neutral position.
FIG. 12 is a perspective view similar to FIG. 11 , showing the swash plate in a stroked position.
FIG. 13 is a side elevational view of a third embodiment of this invention, depicting the swash plate in the neutral position.
FIG. 14 is a view similar to FIG. 13 , with the swash plate in a first stroked position.
FIG. 15 is a view similar to FIGS. 13 and 14 , with the swash plate in a second stroked position.
DETAILED DESCRIPTION OF THE INVENTION
A first embodiment of this invention and in particular return to neutral mechanism 10 is disclosed in FIGS. 1-3 . A second embodiment of the invention and in particular return to neutral mechanism 110 is disclosed in FIGS. 4-12 . A third embodiment of the invention and in particular return to neutral mechanism 210 is disclosed in FIGS. 13-15 .
The general arrangement of the hydrostatic transmission used with these embodiments will be discussed with regard to hydrostatic transmission 120 shown in FIG. 4 . Pump cylinder block 12 is rotatably mounted on center section 114 , which includes internal hydraulic porting (not shown) to transfer hydraulic fluid between pump cylinder block 12 and motor cylinder block 15 . A plurality of pump pistons (not shown) are mounted in cylinder block 12 . Center section 114 and the other components could take on a variety of other shapes and arrangements. By way of example only, the pump and motor cylinder blocks need not be at right angles to one another but could also be in a parallel or back-to-back arrangement, and center section 114 could be formed in the shape of a plate or other structure, or could be formed as part of the housing.
Center section 14 is depicted in FIGS. 2 and 3 in connection with the first embodiment of this invention and while it is a different shape than center section 114 , both can operate in essentially the same manner. In both cases, a motor running surface 18 is provided with a pair of kidney ports 19 to connect motor cylinder block 15 to the internal hydraulic porting (not shown). It will also be understood that the various gears and other components that would be used in connection with this invention if used with a transaxle are not depicted herein.
As shown in, e.g., FIG. 4 , swash plate 122 is used to control the output of hydraulic pump cylinder block 12 ; a swash plate bearing (not shown) located inside swash plate 122 engages with pump pistons (not shown). In neutral, swash plate 122 is generally perpendicular to the rotational axis of pump cylinder block 12 .
Trunnion 124 extends from one side of swash plate 122 and includes a portion 129 engaged to a control mechanism (not shown) located external to housing 150 for causing rotation of swash plate 122 . Trunnion 124 extends from the side of swash plate 122 opposite to the side where the return to neutral mechanism 110 is located. A second support trunnion 126 can be used to support swash plate 122 within housing 150 and would be located on the same side of swash plate 122 as return to neutral mechanism 110 .
A similar arrangement can be used with the other embodiments depicted herein; for example, swash plate 22 in FIGS. 1-3 can use two support trunnions 24 , 26 that are similar in function to that previously described. It will be understood that return to neutral mechanism 10 or 110 could be on the same side as the trunnion 24 or 124 , depending on factors such as housing size and the like. It will also be understood that other methods of supporting a swash plate, such as a cradle bearing, are known and are interchangeable with the use of a pair of opposing trunnions.
In a first embodiment, return to neutral mechanism 10 comprises yoke 32 engaged to load arm 31 and swash plate 22 . At one end of load arm 31 , spring 30 is secured to spring attachment opening 36 and to a fixed point in the housing (not depicted in this embodiment), thus providing the return force to load arm 31 and yoke 32 . In operation load arm 31 pivots about adjustment mechanism 60 , and in particular about the axis of protrusion 49 , described in more detail below. Yoke 32 comprises a pair of arms 33 a and 33 b joined by a curved surface, culminating in a preferably curved end 35 a and 35 b , respectively. Yoke 32 is secured to a side of load arm 31 in a manner to permit its rotation with respect thereto.
As shown most clearly in FIG. 2 , swash plate 22 includes an end portion 25 , which may be integrally formed therewith, and having a generally curved shape culminating in two stops 27 , which are connected by curved interface 23 . Interface 23 preferably has a radius complementary to that of curved surface 38 on yoke 32 . It will be understood that these two surfaces will not actually contact one another when the unit is in neutral, as shown in FIG. 3 , but that there would be a small gap between them, and the contact between yoke 32 and swash plate 22 will be through arms 33 a , 33 b contacting the two stops 27 when the unit is in neutral. The geometry of these components, such as yoke 32 , load arm 31 , location of spring attachment opening 36 , and the like can be modified to change the restoring moment of yoke 32 as a function of the swash angle, depending on the specific application requirements.
The location of the neutral position for swash plate 22 may be adjusted by the externally accessible adjustment mechanism 60 , which is similar in operation to the adjustment mechanism 160 discussed in detail below in connection with the second embodiment of this invention. In general, adjustment mechanism 60 extends through the housing (not shown in this embodiment) so that shoulder 41 engages an internal surface of the housing and threaded portion 43 and adjustment hex 34 are located outside the housing. An off-center protrusion 49 is located on the internal end of adjustment mechanism 60 and is mounted in opening 39 formed in one end of load arm 31 . Since protrusion 49 is off-center with respect to the axis of rotation of adjustment 60 , the position of load arm 31 changes as adjustment mechanism 60 is rotated.
The return to neutral mechanism 10 is bidirectional. One of the arms of yoke 32 can be easily shortened so that only one of the stops 27 is contacted by yoke 32 , in the event one wishes to provide for a unidirectional return to neutral; i.e., providing a return force only when the swash plate is stroked in one direction but not the other. Such a feature is described below in connection with further embodiments.
A second embodiment of this invention showing a bidirectional return to neutral mechanism 110 is depicted in FIGS. 4-12 . The relationship of the return to neutral mechanism 110 and housing 150 can best be understood in connection with the second embodiment of the invention as depicted in, e.g., FIGS. 8 and 9 . This same connection to the housing could be used in connection with the first embodiment of return to neutral mechanism 10 , but the housing is not depicted in FIGS. 1-3 for clarity. It will be understood that many of the same components as described above may be used and similar reference numerals are used for components that may be identical to those previously discussed. For example, the shape of center section 114 is not critical to this invention and different center sections could be used or, as noted above, the invention could be used in a design that does not use a center section.
In this second embodiment, return to neutral mechanism 110 comprises load arm 131 , which is sandwiched between housing 150 and center section 114 . Load arm 131 may also be retained in place by other methods, such as a retaining ring on adjustment mechanism 160 . At one end of load arm 131 , spring 130 is secured to spring attachment hole 136 and to a fixed point, which may be a fastener 151 attached to housing 150 , as shown in FIG. 8 , thus providing the return force to load arm 131 and yoke 132 . The other end of load arm is supported in housing 150 by adjustment mechanism 160 , described below. In operation load arm 131 pivots about adjustment mechanism 160 , and in particular about the axis of protrusion 149 .
The location of the neutral position for swash plate 122 may be adjusted by modifying the set position of load arm 131 ; this is accomplished by means of the externally accessible adjustment mechanism 160 , seen most clearly in FIGS. 9 and 10 . In FIG. 9 certain components such as housing 150 are sectioned, but adjustment mechanism 160 is not sectioned merely for clarity. Adjustment mechanism 160 comprises bearing surface 152 extending through an opening 154 in housing 150 so that shoulder 141 engages an internal surface of housing 150 . An off-center protrusion 149 is located on one end of adjustment mechanism 160 internal to housing 150 ; protrusion 149 is mounted in opening 139 formed in one end of load arm 131 . A threaded portion 143 and adjustment hex 134 are located at the opposite end of adjustment mechanism 160 and are located outside the housing so that a user can adjust mechanism 160 externally, and then lock the unit in the selected position by means of locknut 144 . Seal 145 is used to prevent leakage through opening 152 . Since protrusion 149 rotates with shoulder 141 but is located off-center with respect to the axis of rotation of adjustment 160 , it will move the set position of load arm 131 as adjustment mechanism 160 is rotated. While it is generally intended that the adjustment mechanisms 60 and 160 disclosed herein are used to locate neutral, it will be understood that these mechanisms could also be set to be biased to an off-neutral position, so that yoke 32 or 132 would return swash plate 22 or 122 to some preselected, non-neutral position.
Yoke 132 comprises a pair of arms 133 joined by a curved surface, each arm culminating in a preferably curved end 135 . In the second embodiment, the shapes of yoke 132 and load arm 131 and the relationship between these elements and with swash plate 122 are slightly different than the first embodiment. Yoke 132 includes two arms 133 a , 133 b extending from the main body thereof to engage swash plate 122 and, in particular pockets 128 formed in surfaces 127 . Pockets 128 act as the stops and are shaped to receive curved ends 135 a , 135 b of each arm 133 a , 133 b ; using a curved interaction surface such as pocket 128 as the stop improves the interaction between yoke 132 and swash plate 122 , thereby narrowing the dead band.
Housing interface 155 shown in FIG. 8 may be formed on an internal surface of housing 150 and permits the use of a smaller swash plate than the embodiment shown in. e.g., FIGS. 2 and 3 . In the bidirectional embodiment depicted in, e.g., FIG. 8 , there will be a clearance between housing interface 155 and curved portion 138 of yoke 132 . Housing interface 155 is not depicted in FIGS. 5-7 in order to more clearly show the geometry of the other elements.
Yoke 132 is secured to load arm 131 by means of a protuberance 146 shaped to engage a pocket 148 on load arm 131 , this arrangement is generally less expensive to manufacture than the structure shown in the first embodiment and also maintains the forces between yoke 132 and load arm 131 in the same plane.
A further embodiment is depicted in FIGS. 13-15 , which show a uni-directional return to neutral mechanism 210 , which is similar in many ways to mechanism 110 previously discussed. Many of the same components may be used and similar reference numerals are used for components that may be identical to those previously discussed. For example, load arm 131 and its mounting within the housing can be same as previously described.
In this embodiment, yoke 232 includes protuberance 246 mounted into pocket 148 on load arm 131 . Yoke 232 includes, however, only one arm 233 a , with the other arm removed. Thus, when swash plate 122 is stroked in the direction shown in FIG. 15 , a return force is provided by the interaction of arm 233 a with swash plate 122 , and more particularly with the interaction of curved end 235 a with pocket or stop 128 formed in swash plate surface 127 . In this unidirectional embodiment as opposed to the prior bidirectional embodiment, curved portion 238 of yoke 232 interacts with housing interface 155 so that there is no clearance between these two elements.
When swash plate 122 is stroked in the first direction such as is depicted in FIG. 14 , there is no contact between swash plate 122 and yoke 232 , so that no return force is provided in this direction. Note that the same swash plate 122 as previously described is used in this embodiment, to minimize the number of components needed for different applications. If desired, one could use a different swash plate having only the one stop 128 needed. Similarly, the same housing as in the prior embodiments could be used. As shown in FIG. 13-15 , a housing interface 155 may be used in this unidirectional embodiment
It is to be understood that the above description of the invention should not be used to limit the invention, as other embodiments and uses of the various features of this invention will be obvious to one skilled in the art. This invention should be read as limited by the scope of its claims only.
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In a hydrostatic device using an axial piston pump, a yoke is mounted so that it contacts the movable swash plate of the hydrostatic transmission. The yoke is biased by a spring-type mechanism to force the swash plate to return to neutral, and the set position of the yoke plate may be externally adjusted. A bias or load arm rotatably fixed to a housing at one end and connected to a spring at the other end is engaged to the yoke to provide the return force to the yoke plate. The yoke plate may have two legs to provide a return to neutral force to the swash plate in either direction, or one leg to provide the return to neutral force in only a single direction.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional application 60/579,883 filed Jun. 15, 2004, and hereby incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
BACKGROUND OF THE INVENTION
[0002] The present invention relates to automatic dishwashing machines (dishwashers) and in particular to a dishwasher vent for use in a low noise dishwasher.
[0003] Dishwashers, such as those found in many homes, provide a chamber holding one or more racks into which eating utensils and cookware may be placed for cleaning. The chamber may be closed by a door opening at the front of the chamber to allow loading and unloading of the chamber.
[0004] The door is closed during a washing cycle to prevent the escape of water sprayed within the volume of the chamber to wash items placed in the rack. Upon completion of the washing cycle, a drying cycle is initiated during which water is drained from the chamber and moist air is discharged through a vent. Cool air pulled into the chamber through a lower vent rapidly dries the heated dishes.
[0005] Dishwashers can be loud, particularly during the washing cycle, with noise coming from the agitated water, movement of the dishes, and the dishwasher mechanism of pump and motor. Some of this noise can be reduced by properly shrouding the washing chamber with acoustically absorbent material, nevertheless, even with a properly shrouded chamber, a substantial amount of noise can escape through the vent by diffraction.
[0006] One method of reducing vent-transmitted noise is by offsetting the inlet and outlet of the vent to provide a baffling that prevents direct passage of sound through the vent opening. This approach can also prevent water from passing through the vent.
[0007] A second method of reducing vent-transmitted noise is to close the vent with a valve plate or similar mechanism during the washing cycle and open the vent only during the drying cycle. A vent suitable for this purpose is described in U.S. Pat. No. 6,293,289 filed Nov. 8, 1999, assigned to the assignee of the present invention, and hereby incorporated by reference. This patent describes, in one embodiment, a wax motor operating a hinged valve plate that opens and closes to control air and sound flow through the vent. The hinged plate may also be independently opened by excess pressure in the washing machine so as to accommodate “surge pressures” resulting, for example, from pressure build up caused by an opening and closing of the dishwasher in mid-cycle where introduced cold air is rapidly heated by dishes and hot water when the door is resealed.
[0008] Superior drying requires that the vent area be made as large as possible when the vent is open and that the valve plate provide minimal obstruction to the flowing air. This may be done by placing the hinge axis of the valve plate generally parallel to the front and rear surfaces so that the valve plate opens to align with the natural flow lines of air.
[0009] The actuator for a valve plate in a vent may be positioned outside of the vent housing (defining the vent passage) to improve airflow and to protect the actuator from water. This may be accomplished by extending the shaft about which the vent plate rotates out of the vent housing through a journal hole in one wall of the vent to be engaged by an actuator. The journal hole is kept small to prevent the escape of water from the vent and may include a seal.
[0010] Mechanically, passing the shaft through a wall of the vent housing requires either that the vent plate be detachable from the shaft, so that the shaft may be inserted through a journal hole into the housing without obstruction, or that the housing be separable into two halves to allow an integral vent plate/shaft assembly to be positioned in the vent body and the housing closed over that. Both of these approaches increase the complexity of manufacturing the vent: the former requiring assembly of the shaft and vent plate from inside of the vent, and the latter requiring assembly of the vent housing from several pieces.
BRIEF SUMMARY OF THE INVENTION
[0011] The present invention employs a cam drive mechanism moving a valve plate within a dishwasher vent without the need for a direct connection between an actuator and the shaft about which the valve plate rotates. This approach allows the valve plate shaft to be retained wholly within the vent housing eliminating leaks along a rotating shaft passing through the housing or excess shaft friction, and allowing the vent housing to be molded or preassembled as one piece with the valve plate is snapped into place subsequent to the molding.
[0012] The drive mechanism allows the axis of the valve plate and the drive actuator (preferably a wax motor) to be parallel and closely adjacent to the valve plate pivot axis, providing an extremely compact mechanism that may fit easily between the front and rear panel of a dishwasher door. This advantage also applies to an embodiment in which the valve plate is supported by externally inserted pins or the like.
[0013] In one embodiment, the cam mechanism may open and close the valve plate without the need for a biasing spring element or reliance on gravity, and may accommodate over travel common in wax motors while still providing a large amount of mechanical amplification to fully open and close the valve plate with small amounts of actuator travel.
[0014] In one embodiment, the operator may extend along an axis parallel to, but displaced from, a pivot axis of the valve plate to provide an extremely compact assembly.
[0015] In one embodiment, a spring biases the valve plate to allow the valve plate to open independently of the wax motor to relieve surge pressures.
[0016] In one embodiment, an elastomeric seal is held in cantilevered fashion at the valve seat to provide a compliant seal blocking sound transmission.
[0017] These particular objects and advantages may apply to only some embodiments falling within the claims and thus do not define the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a simplified view of a dishwasher in perspective showing location of a door vent for venting moist air;
[0019] FIG. 2 is an exploded perspective view of the door vent of FIG. 1 as viewed from the inside of the dishwasher and as may be positioned between the front and rear door surfaces;
[0020] FIG. 3 is a cross-sectional view of the inlet port of the vent of FIG. 2 taken along lines 3 - 3 showing a snap-in engagement of an integrated vent plate and shaft at the inlet port;
[0021] FIG. 4 is a cross-sectional view taken along lines 4 - 4 of FIG. 3 showing the vent plate in a closed configuration for blocking sound and the flow of air;
[0022] FIG. 5 is a perspective view of the engagement between a wax motor actuator and a cam surface on the vent plate of FIG. 4 as viewed from inside the vent housing;
[0023] FIGS. 6 a through 6 c are rear elevational views of the cam surface with the vent plate in three states of closed, transition, and open;
[0024] FIG. 7 is a figure similar to that of FIG. 4 showing an alternative embodiment of the door vent in which the valve plate may move independently in response to surge pressures; and
[0025] FIG. 8 is a figure similar to FIG. 7 showing an alternative embodiment in which the valve plate has a default open position if the wax motor is removed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] Referring now to FIG. 1 , a dishwasher 10 may include a housing 12 holding a washing chamber and a front door 14 that may be opened to obtain access to the washing chamber for loading and unloading of dishes. A door vent 16 provides an outlet port 18 in the front surface 20 of the door 14 to allow for the escape of moist air 22 .
[0027] Referring now to FIG. 2 , a vent housing 24 provides an air passage between the outlet port 18 on the front surface 20 and an inlet port 26 opening at the rear surface 28 of the door 14 facing the washing chamber. The outlet port 18 is positioned higher on the door than the inlet port 26 , both to provide a serpentine path for muting sound passing through the vent housing 24 and to cause water splashed into and condensation forming within the vent housing to drain downward out of inlet port 26 back into the wash chamber. Preferably, the vent housing 24 is manufactured as a single injection molded part avoiding a need for subsequent assembly of multiple components using screws or welds and eliminating the need to test for leakage of the seams or to provide expensive gasketing at the seams.
[0028] The air passage of the vent housing 24 is substantially continuous to prevent leakage of water into the door 14 , with the exception of a bore 30 opening between inlet port 26 and outlet port 18 , generally perpendicular to the airflow. The bore 30 may be created during the molding of the vent housing 24 using an injection mold with a removable core pin as is understood in the art.
[0029] The bore 30 allows an operator 32 of a wax motor 34 (the wax motor 34 positioned outside the vent housing 24 ) to enter the air passage. The operator 32 of the wax motor 34 has an o-ring seal 36 allowing movement of the operator within the bore 30 without the leakage of liquid there through as will be described below.
[0030] Referring still to FIG. 2 , the inlet port 26 is covered at the rear surface 28 of the door 14 by a removable vent cap 40 that attaches to the vent housing 24 by a twist lock formed from a set of interengaging tabs 41 molded into both the vent cap 40 and the inlet port 26 . The vent cap 40 provides an aperture 42 aligning with the opening of the inlet port 26 and the aperture 42 is covered by a grating 44 so as to deflect water and food particles away from the passageway of the vent housing 24 .
[0031] The vent cap 40 also provides a rear facing valve seat ring 46 extending into the inlet port 26 . This valve seat ring 46 cooperates with a valve plate 48 removably attached within the inlet port 26 to hinge about a hinge axis 51 . The hinge axis 51 is located beneath the valve plate 48 in a horizontal plane and is parallel to the front surface 20 and rear surface 28 .
[0032] When the valve plate 48 is in a closed position as shown in FIG. 4 , a rubber disk 50 forming the inner surface of the valve plate 48 abuts the edge of the valve seat ring 46 blocking the flow of moist air 22 into the vent passageway and providing a barrier against sound 52 . The rubber disk 50 is supported from front and its side removed from the vent cap 40 by a support disk 54 of slightly smaller diameter than the rubber disk 50 so that the peripheral edge of the rubber disk 50 extends in cantilevered fashion from the peripheral edge of the support disk 54 so as to flex to accommodate slight irregularities in the valve seat ring 46 of the vent cap 40 .
[0033] Referring now to FIG. 3 , the support disk 54 of the valve plate 48 includes four hooked tabs 56 extending through corresponding holes in the rubber disk 50 . The rubber disk 50 may be stretched to fit over the hooked tabs and thereby retained against the support disk 54 by the hooks on the hooked tabs 56 . Sizes of the openings 58 in the rubber disk 50 are relatively small being typically substantially less than 1/10th the total area of the rubber disk 50 . Accordingly, as shown in FIG. 4 , the rubber disk 50 covers the majority and the center of the support disk 54 providing improved sound absorption when the valve plate 48 is closed in comparison to systems which use an annular rubber gasket. Using a substantially continuous rubber disk 50 also provides a cost savings by eliminating the need for a thicker support disk 54 for sound absorption and by making use of the center portions of the rubber disk 50 that might otherwise be removed and discarded in the fabrication of a washer shape.
[0034] Referring now to FIGS. 2 and 3 , the support disk 54 has downwardly extending legs 60 supporting horizontal and opposed outwardly extending pivot pins 62 defining the hinge axis 51 described above. The support disk 54 , the leg 60 , and the pins 62 may be constructed of a material, such as injection moldable thermoplastic, providing sufficient flexibility so that the legs 60 may be compressed inward in order for the pins 62 to snap into corresponding pivot sockets 64 molded in the interior of the housing 24 adjacent to the inlet port 26 . The sockets 64 are blind, that is, they do not lead from the inside of the vent housing 24 to the outside of the vent housing 24 , and therefore the sockets 64 provide no passage for water or moisture splashing into the vent housing 24 to leak into the door 14 . Eliminating the need for the shaft supporting the valve plate 48 to pass wholly through the vent housing 24 simplifies single piece injection molding of the vent housing 24 , improves the integrity of the vent housing 24 , and reduces resistance of valve plate 48 to movement about the hinge axis 51 by allowing a small contact area between the pins 62 and sockets 64 .
[0035] The present invention also contemplates an alternate embodiment in which one or more metal pins (not shown) may be pressed into through holes aligned with but replacing the sockets 64 and serving as an axle for the valve plate 48 . As before, the advantages of being able to produce a single piece molding of the vent housing 24 , of limiting the path of water leakage, and of avoiding the excess resistance of a rotating drive shaft may be obtained.
[0036] Referring now to FIGS. 4 and 5 , actuation of the valve plate 48 is accomplished without external access to a supporting shaft of the valve plate 48 by a cam drive mechanism. As mentioned above, the operator 32 of the wax motor 34 may extend into the vent housing 24 through bore 30 . The end of the operator 32 has a ball tip 70 that engages a cam 72 extending from the side of the support disk 54 removed from the vent cap 40 . The cam 72 provides actuation surfaces that form a Z-shaped channel capturing the ball tip 70 and thus allowing opening and closing of the valve plate 48 with extension and retraction of the operator 32 by the wax motor 34 . The ball tip 70 may include a hook (not shown) to provide improved engagement with the cam 72 as will be understood to those of ordinary skill in the art.
[0037] Generally, the extension axis 74 of the operator 32 is parallel to the hinge axis 51 with the ball tip 70 of the operator 32 positioned closely to the hinge axis 51 . This produces an extremely compact mechanism and one that is desirably sensitive to small motions of the operator 32 . Yet the range of travel of the operator 32 of a wax motor 34 can vary over time, so capture of the ball tip 70 by the cam 72 requires an accommodation of assembly tolerance and over travel of the operator 32 .
[0038] Referring now to FIG. 6 , this accommodation is provided by creating over travel and under travel portions of the cam 72 . When the ball tip 70 is in its further extent from the wax motor (to the left in FIG. 6 a ), it is in the over travel position 79 and contacts cam surface 76 which extend generally horizontally so that further travel of the ball tip 70 does not provide further torsion or twisting of the valve plate 48 about the hinge axis 51 . In this over travel position 79 , the valve plate 48 is closed against the valve seat ring 46 as shown in FIG. 4 . Surface 77 may lie on a radius about axis 51 to allow free rotation of valve plate 48 in a closing direction without interference between the ball tip 70 and surface 77 , reflecting the constant radial distance between ball tip 70 and axis 51 . Ultimately, closing of the valve plate 48 is limited by the engagement of the valve plate 48 and the valve seat ring 46 .
[0039] When the ball tip 70 is retracted somewhat, it moves to an actuation position 82 as shown in FIG. 6 b , the ball tip 70 now held captive between upper surface 84 and lower cam surface 78 diagonal to the hinge axis 51 and causing an opening or closing of the valve plate 48 with retraction or extension of the ball tip 70 . This actuation position 82 may be relatively short and may be fit easily within the assured operating range of the wax motor 34 during its lifetime or caused by unit-to-unit variation.
[0040] As shown in FIG. 6 c , when the ball tip 70 is closest to the wax motor 34 , for example, prior to closure of the valve plate 48 or after opening of the valve plate 48 , it is held captive between surfaces 90 and 92 on its top and bottom sides in an under travel position 86 . The surfaces 90 and 92 are essentially horizontal so that the ball tip 70 may be threaded into engagement with the cam 72 when the wax motor 34 is installed on the housing 24 . Thus, over travel and under travel may be accommodated while maintaining a close coupling between the ball tip 70 and the cam 72 .
[0041] Referring now to FIG. 7 , in a second embodiment, the cam 72 may be modified to remove the surfaces 76 , 84 , and 90 shown in FIGS. 6 a , 6 b , and 6 c . As described above, these surfaces are used to allow extension of the ball tip 70 to close the valve plate 48 . Surfaces 78 and 92 which allow the ball tip 70 to open the valve plate 48 , remain in place. As a result, the entire surface of the cam 72 above surfaces 78 and 92 is lies on a constant radius about axis 51 to allow free rotation of valve plate 48 in a closing direction without interference between the ball tip 70 and surface 77
[0042] Closing of the valve plate 48 is performed in this embodiment by a helical compression spring 94 placed between the rear surface of the support disk 54 and a front surface of the rear wall of the housing 24 . Normally this spring 94 causes the valve plate 48 to close against the valve seat ring 46 absent contact between the ball tip 70 and the cam surfaces 78 or 92 . Moist air 22 of a predetermined pressure (for example, one half inch of water) as selected by varying the force of the spring 94 and the area of the valve plate 48 , will allow the valve plate 48 to swing open independent of the position of the ball tip 70 to relieve surge pressures as required.
[0043] In the absence of surge pressure, the valve plate 48 may be opened by the ball tip 70 interacting with cam surfaces 78 and 92 as described above. Other methods of biasing the valve plate 48 closed including gravity or other types of springs may also be employed as will be understood to those of ordinary skill in the art.
[0044] Referring now to FIG. 8 , an alternative embodiment of the door vent 16 provides both the surge pressure release, described above, and a default open position for the valve plate 48 . This default to an open position allows air to pass through the door vent 16 should the wax motor 34 (described above) be removed or the ball tip 70 and/or its connecting shaft be broken or damaged in such a way as to disengage from the cam 72 . In this way, the risk of suffocation to a child entrapped in a dishwasher that has been abandoned or partially disassembled is reduced.
[0045] In contrast to the embodiment shown in FIG. 7 in which compression spring 94 is used to close the valve plate 48 , in the embodiment of FIG. 8 , a torsion spring 100 is placed about pivot axis 51 so as to provide a clockwise bias 109 to the cam 72 about the hinge axis 51 . The bias provided by torsion spring 100 opens the valve plate 48 absent countervailing force by the ball tip 70 on the cam surface 76 (also shown in FIGS. 6 a - c ).
[0046] In this embodiment, the support disk 54 of the valve plate 48 is not rigidly attached to the cam 72 , but may pivot with respect to the cam 72 about a second hinge axis 102 on the cam 72 . A helical compression spring 104 fits between the rear surface of the support disk 54 and the front surface of an extension 106 to the cam 72 , so that the support disk 54 is biased forward toward the valve seat ring 46 in a counter-clockwise direction 108 about hinge axis 102 .
[0047] Movement of the support disk 54 in the counter-clockwise direction 108 is limited by a stop 110 extending rearward from the support disk 54 to oppose a rear surface of the upward extension 106 , allowing only limited relative travel between the support disk 54 and the cam 72 in a counter-clockwise direction 108 .
[0048] It will be understood from this description, that removal of the ball tip 70 will cause the cam 72 to move in a clockwise direction under the bias of the torsion spring 100 . This will cause valve plate 48 to open after its forward travel in a counter-clockwise direction 108 under the urging of spring 104 and is stopped by stop 110 .
[0049] Conversely in normal operation, when the ball tip 70 is fully extended from the wax motor 34 , the cam 72 is rotated in a counter-clockwise direction pressing the valve plate 48 and the rubber disk 50 against the valve seat ring 46 to close the vent. The helical compression spring 104 allows some over-travel of the cam 72 with no adverse effect.
[0050] In this position, a surge pressure of moist air 22 can nevertheless push against the valve plate 48 causing clockwise rotation against the spring 104 as described previously to open the valve plate 48 without movement of the cam 72 .
[0051] It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims.
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A mechanized vent for a dishwasher employs a vent plate moving about a hinge axis as driven by a cam mechanism at a surface of the vent plate removed from the hinge axis.
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FIELD OF THE INVENTION
The invention relates to genetically engineered Candida tropicalis cells, use thereof and a method of production of ω-hydroxycarboxylic acids and ω-hydroxycarboxylic acid esters.
BACKGROUND OF THE INVENTION
Owing to its ability to form dicarboxylic acids from alkanes, Candida tropicalis is a well-characterized ascomycete.
WO91/006660 describes Candida tropicalis cells that are completely inhibited in β-oxidation through interruption of the PDX4 and/or PDX5 genes, and achieve increased yields of α,ω-dicarboxylic acids.
WO00/020566 describes cytochrome P450 monooxygenases and NADPH cytochrome P450 oxidoreductases from Candida tropicalis and use thereof for influencing ω-hydroxylation, the first step in ω-oxidation.
WO03/089610 describes enzymes from Candida tropicalis which catalyse the second step of ω-oxidation, the conversion of a fatty alcohol to an aldehyde, and use thereof for improved production of dicarboxylic acids.
The cells and methods described so far are not suitable for the production of ω-hydroxycarboxylic acids or their esters, as the ω-hydroxycarboxylic acids are always only present as a short-lived intermediate and are immediately metabolized further.
ω-Hydroxycarboxylic acids and their esters are economically important compounds as precursors of polymers, and this forms the basis of the commercial usability of the present invention.
The task of the invention was to find a way of preparing ω-hydroxycarboxylic acids or ω-hydroxycarboxylic acid esters by fermentation in sufficient amounts, in particular in the medium surrounding the cells.
DESCRIPTION OF THE INVENTION
It was found, surprisingly, that the cells described hereunder make a contribution to solution of this task.
The object of the present invention is therefore a cell as described in claim 1 .
Another object of the invention is the use of the cell according to the invention and a method of production of ω-hydroxycarboxylic acids and ω-hydroxycarboxylic acid esters using the cells according to the invention.
Advantages of the invention are the gentle conversion of the educt used to the ω-hydroxycarboxylic acids and corresponding esters and a high specificity of the method and an associated high yield based on the educt used.
One object of the present invention is a Candida tropicalis cell, in particular one from the strain ATCC 20336, which is characterized in that the cell has, compared with its wild type, a reduced activity of at least one of the enzymes that are encoded by the intron-free nucleic acid sequences selected from the two group comprising
A) Seq ID No. 1, Seq ID No. 3, Seq ID No. 5, Seq ID No. 7, Seq ID No. 9, Seq ID No. 11, Seq ID No. 13, Seq ID No. 15, Seq ID No. 17, Seq ID No. 19, Seq ID No. 21, Seq ID No. 23, Seq ID No. 25, Seq ID No. 27, Seq ID No. 29, Seq ID No. 31, Seq ID No. 33, Seq ID No. 35, Seq ID No. 37, Seq ID No. 39, Seq ID No. 41, Seq ID No. 43, Seq ID No. 45, Seq ID No. 47, Seq ID No. 49, Seq ID No. 51, Seq ID No. 53, Seq ID No. 55, Seq ID No. 57, Seq ID No. 59, Seq ID No. 61, Seq ID No. 63, Seq ID No. 65 and Seq ID No. 67; in particular Seq ID No. 1, Seq ID No. 3, Seq ID No. 5, Seq ID No. 7, Seq ID No. 9, Seq ID No. 11, Seq ID No. 13, Seq ID No. 15, Seq ID No. 17, Seq ID No. 19, Seq ID No. 21, Seq ID No. 23, Seq ID No. 25, Seq ID No. 27, Seq ID No. 29, Seq ID No. 31, Seq ID No. 33, Seq ID No. 35, Seq ID No. 37, Seq ID No. 39, Seq ID No. 41, Seq ID No. 43, Seq ID No. 45, Seq ID No. 47, Seq ID No. 49 and Seq ID No. 51; quite especially Seq ID No. 1, Seq ID No. 3, Seq ID No. 5, Seq ID No. 7, Seq ID No. 9, Seq ID No. 11, Seq ID No. 13, Seq ID No. 15, Seq ID No. 17, Seq ID No. 19, Seq ID No. 21, Seq ID No. 23, Seq ID No. 25 and Seq ID No. 27, B) a sequence that is identical to at least 80%, especially preferably to at least 90%, even more preferably to at least 95% and most preferably to at least 99% to one of the sequences Seq ID No. 1, Seq ID No. 3, Seq ID No. 5, Seq ID No. 7, Seq ID No. 9, Seq ID No. 11, Seq ID No. 13, Seq ID No. 15, Seq ID No. 17, Seq ID No. 19, Seq ID No. 21, Seq ID No. 23, Seq ID No. 25, Seq ID No. 27, Seq ID No. 29, Seq ID No. 31, Seq ID No. 33, Seq ID No. 35, Seq ID No. 37, Seq ID No. 39, Seq ID No. 41, Seq ID No. 43, Seq ID No. 45, Seq ID No. 47, Seq ID No. 49, Seq ID No. 51, Seq ID No. 53, Seq ID No. 55, Seq ID No. 57, Seq ID No. 59, Seq ID No. 61, Seq ID No. 63, Seq ID No. 65 and Seq ID No. 67; in particular to Seq ID No. 1, Seq ID No. 3, Seq ID No. 5, Seq ID No. 7, Seq ID No. 9, Seq ID No. 11, Seq ID No. 13, Seq ID No. 15, Seq ID No. 17, Seq ID No. 19, Seq ID No. 21, Seq ID No. 23, Seq ID No. 25, Seq ID No. 27, Seq ID No. 29, Seq ID No. 31, Seq ID No. 33, Seq ID No. 35, Seq ID No. 37, Seq ID No. 39, Seq ID No. 41, Seq ID No. 43, Seq ID No. 45, Seq ID No. 47, Seq ID No. 49 and Seq ID No. 51; quite especially to Seq ID No. 1, Seq ID No. 3, Seq ID No. 5, Seq ID No. 7, Seq ID No. 9, Seq ID No. 11, Seq ID No. 13, Seq ID No. 15, Seq ID No. 17, Seq ID No. 19, Seq ID No. 21, Seq ID No. 23, Seq ID No. 25 and Seq ID No. 27.
In this connection, the nucleic acid sequence group that is preferred according to the invention is group A).
A “wild type” of a cell preferably means, in connection with the present invention, the starting strain from which the cell according to the invention was derived by manipulation of the elements (for example the genes comprising the aforesaid nucleic acid sequences coding for a corresponding enzyme or the promoters contained in the corresponding gene, which are linked functionally with the aforesaid nucleic acid sequences), which influence the activities of the enzymes encoded by the stated nucleic acid Seq ID No. If for example the activity of the enzyme encoded by Seq ID No. 1 in the strain ATCC 20336 is reduced by interruption of the corresponding gene, then the strain ATCC 20336 that is unchanged and was used for the corresponding manipulation is to be regarded as the “wild type”.
The term “gene” means, in connection with the present invention, not only the encoding DNA region or that transcribed to mRNA, the “structural gene”, but in addition promoter, possible intron, enhancer and other regulatory sequence, and terminator, regions.
The term “activity of an enzyme” always means, in connection with the invention, the enzymatic activity that catalyses the reactions of 12-hydroxydodecanoic acid to 1,12-dodecane diacid by the entire cell. This activity is preferably determined by the following method:
Starting from a single colony, a 100-ml Erlenmeyer flask with 10 ml of YM medium (0.3% yeast extract, 0.3% malt extract, 0.5% peptone and 1.0% (w/w) glucose) is cultivated at 30° C. and 90 rpm for 24 h. Then, starting from this culture, 10 ml is inoculated into a 1-litre Erlenmeyer flask with 100 ml of production medium (for 1 litre: 25 g glucose, 7.6 g NH 4 Cl, 1.5 g Na 2 SO 4 , 300 ml of a 1 mM potassium phosphate buffer (pH 7.0), 20 mg ZnSO 4 ×7H 2 O, 20 mg MnSO 4 ×4H 2 O, 20 mg nicotinic acid, 20 mg pyridoxine, 8 mg thiamine and 6 mg pantothenate). It is cultivated for 24 h at 30° C.
After 24 h, 12-hydroxydodecanoic acid is added to the cell suspension, so that the concentration is not greater than 0.5 g/l. Glucose or glycerol is also added as co-substrate, so that the concentration of the co-substrate does not drop below 0.2 g/l. After Oh, 0.5 h, 1 h, and then hourly up to a cultivation time of 24 h, samples (1 ml) are taken for measurement of 12-hydroxydodecanoic acid, 12-oxo-dodecanoic acid and 1,12-dodecane diacid and the corresponding methyl esters, and for checking the cell count. After each measurement, the pH is kept between 5.0 and 6.5 with 6N NaOH or 4NH 2 SO 4 . During cultivation, cell growth is verified by checking the “colony forming units” (CFU). The decrease of 12-hydroxydodecanoic acid and the production of 1,12-dodecane diacid or the corresponding methyl esters are verified by LC-MS. For this, 500 μl of culture broth is adjusted to pH 1 and then extracted with the same volume of diethyl ether or ethyl acetate and analysed by LC-MS.
The measuring system consists of an HP1100 HPLC (Agilent Technologies, Waldbronn, Germany) with degasser, autosampler and column furnace, coupled to a mass-selective quadrupole detector MSD (Agilent Technologies, Waldbronn, Germany). Chromatographic separation is achieved on a reversed phase e.g. 125×2 mm Luna C18(2) column (Phenomenex, Aschaffenburg, Germany) at 40° C. Gradient elution is performed at a flow of 0.3 ml/min (A: 0.02% formic acid in water and B: 0.02% formic acid in acetonitrile). Alternatively, the organic extracts are analysed by GC-FID (Perkin Elmer, Rodgau-Jügesheim, Germany). Chromatographic separation is performed on a methylpolysiloxane (5% phenyl) phase e.g. Elite 5, 30 m, 0.25 mm ID, 0.25 μm FD (Perkin Elmer, Rodgau-Jügesheim, Germany). Before measurement, a methylation reagent e.g. trimethylsulphonium hydroxide “TMSH” (Macherey-Nagel GmbH & Co. KG, Düren, Germany) is added to free acids and on injection they are converted to the corresponding methyl esters.
By calculating the measured concentration of 1,12-dodecane diacid and the cell number at the time of sampling, it is possible to determine the specific production rate of 1,12-dodecane diacid from 12-hydroxydodecanoic acid and therefore the “activity of an enzyme” in a cell as defined above. The formulation “reduced activity compared with its wild type” means an activity relative to the wild-type activity preferably reduced by at least 50%, especially preferably by at least 90%, more preferably by at least 99.9%, even more preferably by at least 99.99% and most preferably by at least 99.999%.
The decrease in activity of the cell according to the invention compared with its wild type is determined by the method described above for determining activity using cell numbers/concentrations as identical as possible, the cells having been grown under the same conditions, for example medium, gassing, agitation.
“Nucleotide identity” relative to the stated sequences can be determined using known methods. Generally, special computer programs are used with algorithms taking special requirements into account. Preferred methods for determining identity first produce the greatest agreement between the sequences to be compared. Computer programs for determining identity comprise, but are not restricted to, the GCG software package, including
GAP (Deveroy, J. et al., Nucleic Acid Research 12 (1984), page 387, Genetics Computer Group University of Wisconsin, Medicine (Wi), and BLASTP, BLASTN and FASTA (Altschul, S. et al., Journal of Molecular Biology 215 (1990), pages 403-410. The BLAST program can be obtained from the National Center for Biotechnology Information (NCBI) and from other sources (BLAST Manual, Altschul S. et al., NCBI NLM NIH Bethesda ND 22894; Altschul S. et al., above).
The known Smith-Waterman algorithm can also be used for determining nucleotide identity.
Preferred parameters for the determination of “nucleotide identity” are, when using the BLASTN program (Altschul, S. et al., Journal of Molecular Biology 215 (1990), pages 403-410):
Expect Threshold: 10 Word size: 28 Match score: 1 Mismatch score: −2 Gap costs: linear
The above parameters are the default parameters in nucleotide sequence comparison.
The GAP program is also suitable for use with the above parameters.
An identity of 80% according to the above algorithm means, in connection with the present invention, 80% identity. The same applies to higher identities.
The term “that are encoded by the intron-free nucleic acid sequences” makes clear that in a sequence comparison with the sequences given here, the nucleic acid sequences to be compared must be purified of any introns beforehand.
All stated percentages (%) are percentages by weight unless stated otherwise.
Methods of lowering enzymatic activities in microorganisms are known by a person skilled in the art.
In particular, techniques in molecular biology can be used for this. A person skilled in the art can find instructions on modification and decrease of protein expression and the associated decrease in enzyme activity especially for Candida tropicalis , in particular for interrupting specified genes, in WO91/006660; WO03/100013; Picataggio et al. Mol Cell Biol. 1991 September; 11(9):4333-9; Rohrer et al. Appl Microbiol Biotechnol. 1992 February; 36(5):650-4; Picataggio et al. Biotechnology (NY). 1992 August; 10(8):894-8; Ueda et al. Biochim Biophys Acta. 2003 Mar. 17; 1631(2):160-8; Ko et al. Appl Environ Microbiol. 2006 June; 72(6):4207-13; Hara et al. Arch Microbiol. 2001 November; 176(5):364-9; Kanayama et al. J. Bacteriol. 1998 February; 180(3): 690-8.
Cells preferred according to the invention are characterized in that the decrease in enzymatic activity is achieved by modification of at least one gene comprising one of the sequences selected from the previously stated nucleic acid sequence groups A) and B), the modification being selected from the group comprising, preferably consisting of, insertion of foreign DNA into the gene, deletion at least of parts of the gene, point mutations in the gene sequence and subjecting the gene to the influence of RNA interference or exchange of parts of the gene with foreign DNA, in particular of the promoter region.
Foreign DNA means, in this context, any DNA sequence that is “foreign” to the gene (and not to the organism), i.e. even Candida tropicalis endogenous DNA sequences can, in this context, function as “foreign DNA”.
In this context, it is in particular preferable for the gene to be interrupted by insertion of a selection marker gene, therefore the foreign DNA is a selection marker gene, the insertion preferably having been effected by homologous recombination into the gene locus.
In this context, it may be advantageous if the selection marker gene is expanded with further functionalities, which in their turn make subsequent removal from the gene possible, this can be achieved for example with a Cre/loxP system, with Flippase Recognition Targets (FRT) or by homologous recombination.
Cells preferred according to the invention are characterized in that they are blocked in their β-oxidation at least partially, preferably completely, as this prevents outflow of substrate and therefore higher titres become possible.
Examples of Candida tropicalis cells partially blocked in their β-oxidation are described in EP0499622 as strains H41, H41B, H51, H45, H43, H53, H534, H534B and H435, from which a Candida tropicalis cell preferred according to the invention is derived.
Other Candida tropicalis cells blocked for β-oxidation are described for example in WO03/100013.
In this context, cells are preferred for which the β-oxidation is caused by an induced malfunction of at least one of the genes PDX2, PDX4 or PDX5.
Therefore, in this context, cells are preferred that are characterized in that a Candida tropicalis cell preferred according to the invention is derived from strains selected from the group comprising ATCC 20962 and the Candida tropicalis HDC100 described in US2004/0014198.
The use of the cells according to the invention for the production of ω-hydroxycarboxylic acids or ω-hydroxycarboxylic acid esters also contributes to solution of the task facing the invention.
In particular, the use of the cells according to the invention for the production of ω-hydroxycarboxylic acids or ω-hydroxycarboxylic acid esters with a chain length of the carboxylic acid from 6 to 24, preferably to 18 and especially preferably 10 to 16 carbon atoms, which are preferably linear, saturated and unsubstituted, and a chain length of the alcohol component of the ester from 1 to 4, in particular 1 or 2 carbon atoms, is advantageous. In this context, it is preferable for the ω-hydroxycarboxylic acids to be 12-hydroxydodecanoic acid and for the ω-hydroxycarboxylic acid ester to be 12-hydroxydodecanoic acid methyl ester.
A preferred use is characterized according to the invention in that preferred cells according to the invention as described above are used.
Another contribution to solving the task facing the invention is made by a method of production of the C. tropicalis cell according to the invention described above comprising the steps:
I) Preparation of a C. tropicalis cell, preferably a cell that is blocked in its β-oxidation at least partially, preferably completely II) Modification of at least one gene comprising one of the intron-free nucleic acid sequences selected from the previously stated nucleic acid sequence groups A) and B) by insertion of foreign DNA, in particular of DNA coding for a selection marker gene, into the gene, deletion of at least parts of the gene, point mutations in the gene sequence and subjecting the gene to the influence of RNA interference or exchange of parts of the gene with foreign DNA, in particular of the promoter region.
Another contribution to solving the task facing the invention is made by a method of production of ω-hydroxycarboxylic acids or ω-hydroxycarboxylic acid esters, in particular of ω-hydroxycarboxylic acids or ω-hydroxycarboxylic acid esters with a chain length of the carboxylic acid from 6 to 24, preferably 8 to 18 and especially preferably 10 to 16 carbon atoms, which are preferably linear, saturated and unsubstituted, and a chain length of the alcohol component of the ester from 1 to 4, in particular of 1 or 2 carbon atoms, in particular of 12-hydroxydodecanoic acid or 12-hydroxydodecanoic acid methyl ester comprising the steps
A) contacting a previously described cell according to the invention with a medium comprising a carboxylic acid or a carboxylic acid ester, in particular a carboxylic acid or a carboxylic acid ester with a chain length of the carboxylic acid from 6 to 24, preferably 8 to 18 and especially preferably 10 to 16 carbon atoms, which are preferably linear, saturated and unsubstituted, and a chain length of the alcohol component of the ester from 1 to 4 carbon atoms, in particular dodecanoic acid or dodecanoic acid methyl ester, B) cultivating the cell under conditions that enable the cell to form the corresponding ω-hydroxycarboxylic acid or ω-hydroxycarboxylic acid esters from the carboxylic acid or the carboxylic acid ester and C) optionally isolating the ω-hydroxycarboxylic acid or ω-hydroxycarboxylic acid esters that formed.
Preferred methods according to the invention use cells stated above as being preferred according to the invention.
Therefore, for example a method of production of 12-hydroxydodecanoic acid or 12-hydroxydodecanoic acid methyl ester comprising the steps
a) contacting a Candida tropicalis cell of the strain ATTC 20336 at least partially blocked in its β-oxidation, which has, compared with its wild type, a reduced activity of at least one of the enzymes, which are encoded by the intron-free nucleic acid sequences selected from the previously stated nucleic acid sequence groups A) and B), the decrease in enzymatic activity being achieved by modification of a gene comprising one of the nucleic acid sequences selected from the previously stated nucleic acid sequence groups A) and B), wherein the modification consists of insertion of a selection marker gene into the gene, with a medium comprising dodecanoic acid or dodecanoic acid methyl ester, b) cultivating the cell under conditions that enable the cell to form the corresponding ω-hydroxycarboxylic acid or ω-hydroxycarboxylic acid esters from the carboxylic acid or the carboxylic acid ester and c) optionally isolating the ω-hydroxycarboxylic acid or ω-hydroxycarboxylic acid esters that formed
is quite especially preferred.
Suitable cultivation conditions for Candida tropicalis are known by a person skilled in the art. In particular, suitable conditions for step b) are those that are known by a person skilled in the art from bioconversion methods of production of dicarboxylic acids with Candida tropicalis.
These cultivation conditions are described for example in WO00/017380 and WO00/015828.
Methods for isolating the ω-hydroxycarboxylic acid or ω-hydroxycarboxylic acid esters that formed are known by a person skilled in the art. These are standard methods for isolating long-chain carboxylic acids from aqueous solution, for example distillation or extraction, and can for example also be found in WO2009/077461.
It is advantageous to use the ω-hydroxycarboxylic acids or ω-hydroxycarboxylic acid esters obtained by the method according to the invention for the production of polymers, in particular polyesters. Moreover, lactones can also be produced from the ω-hydroxy carboxylic acids, and can then for example be used in their turn for the production of polyesters.
Another advantageous use is to convert the ω-hydroxycarboxylic acids or ω-hydroxycarboxylic acid esters to ω-aminocarboxylic acids or ω-aminocarboxylic acid esters, in order to obtain polyamides as polymers. The ω-aminocarboxylic acids or ω-aminocarboxylic acid esters can also be converted first to the corresponding lactams, which can then in their turn be converted using anionic, or also acid catalysis to a polyamide.
It is quite especially advantageous, in a first reaction step, to convert the ω-hydroxycarboxylic acids or corresponding esters into the ω-oxo-carboxylic acids or the corresponding esters and then to carry out amination of the oxo-group, e.g. in the course of reductive amination.
In this context, the use of 12-hydroxy dodecanoic acid or 12-hydroxydodecanoic acid methyl ester for the production of polymers, in particular of polyamide 12, is especially preferred.
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The invention relates to genetically engineered Candida tropicalis cells, use thereof and a method of production of ω-hydroxycarboxylic acids and ω-hydroxycarboxylic acid esters.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority of German application No. 10 2007 034 524.2 filed Jul. 24, 2007, which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
The invention relates to a method for simultaneous gasification of coals of widely differing degrees of coalification, such as brown coals and stone coals, in accordance with the method of entrained flow gasification. The invention allows coals pulverized into pulverized fuel to be converted into synthesis gases in a gasification plant with oxygen or with a gasification means mixture containing free oxygen in the entrained flow.
BACKGROUND OF THE INVENTION
In such cases there is a specific relationship between the degree of coalification of the coals and the volatile component content and the surface structure. Less coalified coals possess a larger content of volatiles as well as a larger internal surface as a result of the pore structure. They are thus more reactive than strongly coalified coals. This characteristic is especially marked between brown coals and stone coals, but also within the stone coals if anthracite is regarded as the most coalified coal and high-volatile coal as the least coalified coal.
For this reason for example brown coals and stone coals are not jointly gasified in accordance with the prior art. The technique of synthesis gas generation in accordance with the method of autothermic entrained flow gasification has been known for many years and is described in detail in H.-D. Schilling “Kohlevergasung (coal gasification)”, Verlag Glückauf 1979 as well as J. Carl et al. “Noell-Konversionsverfahen (Noell conversion process)”, EF-Verlag für Energie and Umwelttechnik GmbH, 1996, Page 33 and 73. Different embodiments of reactors are further shown in EP0677567B1 and DE3534015A1. With a dry pneumatic feed of the pulverized fuel to the gasification reactor in accordance with patent of application number: 10 200 5 047 583.3 such as CN 200 4200 200 7.1 eddying of the pulverized fuel in a dispensing vessel puts it into a fluid state and it is fed by application of a drop in pressure via a pipeline from the eddy layer of the dispensing vessel to the burner of the gasification reactor. The different densities of brown coal and stone coal also mean that their eddy and flow properties are different. To enable these different coals to be conveyed together, specific ranges of grain size of the coals are required.
SUMMARY OF THE INVENTION
Using this prior art as its starting point, the object of the invention is to create a gasification method in which, with a reliable and safe mode of operation, the simultaneous gasification of coals of different degrees of coalification such as brown coals and stone coals is allowed, with the pulverized fuel, consisting of a mixture of the different coals, being fed from a common dispensing system to the gasification reactor.
This object is achieved by the gasification method as claimed in the features of the independent claim.
The coals forming the mixture are thus, to achieve the same speed of conversion, pulverized in the specific specified grain bands, and depending on their degree of coalification, dried to the specific given residual water content.
Subclaims reflect advantageous embodiments of the invention.
The feeding of the pulverized fuel consisting of coals of differing degrees of coalification is achieved as follows:
Because of their different characteristics, the coals of different degrees of coalification are brought to the corresponding water contents and ranges of granulation in separate drying and pulverizing systems
Grain size
Moisture
Fuels
distribution
content
Petrol coke
(low
Anthracite
{close oversize brace}
reactivity
50% < 63 μm
Stone coal
V daf ≦18%)
95Ma % < 200 μm
<2 wt. %
Pyrolysis coke
≧99% < 250 μm
<2 wt. %
98% < 500 μm
Stone coal
≧94% < 250 μm
<2 wt. %
98% < 500 μm
Hard brown coal
≧94% < 250 μm
<8 wt. %
98% < 500 μm
Soft brown coal
≧55% < 100 μm
<12 wt. %
≧97% < 500 μm
The lumps of coal dried and pulverized into dust according to the given specifications are mixed in a separate device and discharged to an operational bunker for storage,
from the operational bunker pressure sluices are alternately filled with the pulverized fuel mixture and pressurized with an inert gas, such as nitrogen, at operating pressure for example,
the pulverized fuel mixture under operating pressure is periodically discharged from the pressure sluices to a dispensing vessel,
by feeding in an eddying and conveyor gas a thick eddy layer is created in the dispensing vessel, from which the pulverized fuel mixture is fed to the burner of the gasification reactor,
by simultaneous feeding in of a gasification means containing free oxygen the pulverized fuel mixture is converted in the gasification reactor into raw synthesis gas.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained below in more detail by one FIGURE and two exemplary embodiments. FIGURE shows a block diagram of the technology.
DETAILED DESCRIPTION OF THE INVENTION
Example 1
A gasification plant is to be set up for an output of 500 MW gross. There is provision for using a mixture of stone coal dust and brown coal dust as fuel. The two coal types are supplied as raw coal and must first be dried and pulverized into coal dust for example. The brown coal is a soft brown coal with a water content of 55% and an ash content of 8% wf as well as a calorific value of 20500 KJ/kg waf the stone coal possesses a water content of 8% as well as an ash content of 12% wf and a calorific value of 29500 KJ/kg waf. The brown coal and the stone coal given in the example are designated coal I and coal II. Because of their different water content and behavior when pulverized, different pulverizing and drying technologies are necessary.
Brown coal I is dried in a drying and pulverizing plant to a residual water content <12 Ma % and crushed to the grain size ≧55 Ma % 100 μm as well as ≧97 Ma % <500 μm into pulverized fuel.
The stone coal II is a low-volatiles, slow-reaction coal with a with a volatile component content ≦18 Ma % waf which is dried to a water content <2 Ma % and brought to a grain band of 50 Ma %<63 μm as well as 95 Ma %<200 μm in the drying and pulverizing unit 2 . Because of their specific grain band and water content both coals can be fed separately or mixed pneumatically according to the principle of high density pneumatic conveying to the gasification reactor. With joint gasification the pulverized fuel flows from the pulverizing and drying units 1 and 2 are fed to a mixing unit 3 in order to achieve as homogeneous a mixture as possible. Then the pulverized mixture reaches the operational bunker 4 , from which the pressure sluices 5 are filled alternately and are pressurized by an inert gas to operational pressure. The dust under operational pressure is in its turn discharged by a gravity conveyor alternately to a dispensing vessel 6 . The emptied sluice 5 is depressurized, filled once again with fuel from the operational bunker 4 , pressurized and can convey its pulverized content into the dispensing vessel 6 once again. Between one and four pressure sluices 5 can be connected to the dispensing vessel 6 , depending on the output. In this example four pressure sluices 5 are needed. The arrangement of a number of pressure sluices 5 allows a continuous operation of the dispensing vessel 6 to be achieved from the discontinuous operation of the pressure sluice 5 . The dispensing vessel 6 has a narrowed area in the lower part in which a fluidized bed ground is employed. By feeding in inert gas 11 a dense fluid layer comprising a pulverized fuel-inert gas suspension is formed above the fluidized bed ground, into which the conveyor lines extend and transport the fuel to the gasification reactor 8 where it is converted with a gasification means containing free oxygen into raw synthesis gas. One or more conveyor lines 7 can be used. The raw synthesis gas travels via the line 10 into downstream cleaning systems. The ash component of the coals converted into granulated slag during the gasification process is removed from the gasification reactor via the line 9 .
Example 2
A gasification plant with the output of example 1 is operated simultaneously with a mixture of a slow-reaction stone coal in accordance with example 1 and a reaction-friendly coal with a volatile component content >18 Ma % waf. The reaction-friendly stone coal is likewise dried to a water content <2 Ma %, the required grain size range is produced from 94 Ma % <250 μm and 98 Ma % <500 μm.
Petrol coke and anthracite behave like the low-volatility stone coals. When hard brown coal is used it must be dried to a residual water content <8 Ma %, the grain distribution of the pulverized fuel created is produced at >94 Ma % <250 μm and 98 Ma % <500 μm. The different pulverized fuels of coals I and II can also be produced externally and fed jointly to the mixing station 3 .
Inventive objects are also produced by the following combinations of features.
A method for gasification of pulverized fuels in an entrained flow gasification reactor at pressures between normal pressure and 80 bar, at temperatures between 1200-1900° C., with an oxidization means containing free oxygen, with the gasification temperature lying so far above the melting temperature of the coal ash that the latter can be removed as a molten flow from the gasification chamber, with mixtures of coals of different degrees of coalification and thereby different reaction capabilities as well as different water content being gasified.
A development of the invention is produced by the previously characterized method in which the coals forming the mixture are pulverized into different grain bands for achieving the same rate of turnover.
A development of the invention is produced by the previously characterized method in which the grain bands are characterized by the following grain size distribution:
Fuels
Grain size distribution
Petrol coke
(low
Anthracite
{close oversize brace}
reactivity
50% < 63 μm
Stone coal
V daf ≦18%)
95Ma % < 200 μm
Pyrolysis coke
≧99% < 250 μm
98% < 500 μm
Stone coal
≧94% < 250 μm
98% < 500 μm
Hard brown coal
≧94% < 250 μm
98% < 500 μm
Soft brown coal
≧55% < 100 μm
≧97% < 500 μm
A development of the invention is produced by the previously characterized method in which the coals are dried, depending on their degree of coalification, to different residual water contents, which are defined as follows:
Fuels
Moisture content
Petrol coke
(low
Anthracite
{close oversize brace}
reactivity
Stone coal
V daf ≦18%)
<2 wt. %
Pyrolysis coke
<2 wt. %
Stone coal
<2 wt. %
Hard brown coal
<8 wt. %
Soft brown coal
<12 wt. %
A development of the invention is produced by the previously characterized method in which the different sorts of coal are fed to different drying and pulverizing systems.
A development of the invention is produced by the previously characterized method in which the different sorts of coal are fed to a common drying and pulverizing system.
A development of the invention is produced by the previously characterized method in which the separately dried and pulverized sorts of coal are mixed homogeneously in a mixing system.
A development of the invention is produced by the previously characterized method in which the pulverized mixtures are put under operational pressure in pressure sluices and conveyed pneumatically as dense gas/pulverized fuel suspensions to the gasification reactor.
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A method for gasification of fuel in an entrained flow of a gasification reactor. The method includes jointly gasifying a mixture of at least two different fuels having different degrees of coalification, including those of differing coal qualities such as brown coals and stone coals. The method also includes pulverizing the coals forming the mixture in specific grain bands and drying the coals forming the mixture to a specific residual water content.
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The present application is the national phase of International Application No. PCT/CN2012/076529, filed on Jun. 6, 2012, which claims the benefit of priority to Chinese patent application No. 201110161555.0, filed with the Chinese State Intellectual Property Office on Jun. 9, 2011, which applications are hereby incorporated by reference to the maximum extent allowable by law.
TECHNICAL FIELD
The present application relates to a technical field of air conditioning, in particular to an air-conditioning system used in an automobile.
BACKGROUND
Energy saving of an automobile air-conditioning system appears to be quite important as the requirement for the automobile energy saving becomes increasingly higher. In a conventional automobile air-conditioning system, a throttle mechanism generally includes a thermal expansion valve and a throttling short tube. Compared to the conventional throttle mechanism, the electronic expansion valve has a relatively strong advantage in overheat control and overall energy saving since the electronic expansion valve may realize an accurate control.
However, there are some limitations for the application of the electronic expansion valve in the automobile air conditioner, and one main factor is that the electronic expansion valve is an electric component and is difficult to meet a requirement for temperature resistance of the automobile environment. An overly high operating environment temperature may burn and damage the coil of the electronic expansion valve and the control chip, thus the electronic expansion valve cannot work normally, which may in turn affect the operation of the whole air-conditioning system. In order to enhance the level of the temperature resistance of the electronic expansion valve, the volume of the electronic expansion valve must be increased, however the increased volume may not only increase the cost, but also fail to show the application advantages of the electronic expansion valve.
At present, due to the price factor and the technical bottleneck of the electronic expansion valve, the thermal expansion valve is also applied in the new energy automobile air conditioner as well as the conventional gasoline car. Due to influences from factors of weather, road condition, thermal load, engine speed and etc., an automobile air conditioner generally works under a non-standard design working condition. However, the set value of an overheat degree of the thermal expansion valve is set according to a standard working condition. When the system is operated under a non-standard working condition, the overheat degree tends to deviate from the set value of the overheat degree, thereby causing the decrease of the system efficiency and an unstable operation, and causing dew formation or even frost formation on the evaporator under a certain condition.
In an air-conditioning system of an electric automobile, an electronic expansion valve is required to cooperate with a varying speed adjustment of a variable volume electrical compressor. Especially, the electrical compressor works independently in the air-conditioning system of the electric automobile, which is different from that in the gasoline car that the compressor is driven by an engine belt pulley. However, a flow adjusting characteristic of the thermal expansion valve cannot be combined with a frequency conversion characteristic of the electrical compressor, which results in a large power load, and a low travel distance per charge of the electric automobile.
Therefore, the application of the electronic expansion valve in the automobile air-conditioning field appears to be extremely important.
SUMMARY
An object of the present application is to provide an automobile air-conditioning system to solve the defect in the prior art that the electronic expansion valve is difficult to meet the requirement for temperature resistance of the automobile environment, and the automobile air-conditioning system has a compact structural design, may effectively cool the electronic expansion valve, and has a high system strength, a stable transmission of refrigerant and a high security.
In order to solve the defect in the prior art, an automobile air-conditioning system is provided, which includes an evaporator and an electronic expansion valve which are communicated with each other via a pipeline, the electronic expansion valve including a coil and a valve body, and the coil being fixedly mounted on the valve body, wherein the automobile air-conditioning system further includes a bracket, the bracket includes a heat dissipation bridge and a cooling ring, the evaporator is arranged at one side of the heat dissipation bridge, the cooling ring is arranged at the other side of the heat dissipation bridge, the heat dissipation bridge and the cooling ring are integrally formed or are fixedly connected, and the coil is arranged in the cooling ring.
Preferably, the side of the heat dissipation bridge close to the evaporator is in direct contact with the evaporator.
Preferably, the side of the heat dissipation bridge close to the evaporator and the evaporator are fixedly connected to be in direct contact with one another.
Preferably, the coil is in direct contact with the cooling ring.
Preferably, the coil and the cooling ring are fixedly connected to be in direct contact with one another.
Preferably, a cover configured to enclose the coil is arranged on the cooling ring, and the cover and the cooling ring are integrally formed or are fixedly connected.
Preferably, the cover has no opening and completely encloses a top portion of the coil, or the cover has an opening and partially encloses a top portion of the coil.
Preferably, the cooling ring is of a complete ring body structure.
Preferably, the cooling ring has a gap, the cooling ring having the gap includes two connecting ends, the two connecting ends are two ring body extending portions extending outwardly from end portions of a ring body at the gap and arranged opposite to each other, and the two connecting ends are fixedly connected via a bolt.
Preferably, the bracket further includes a connecting plate, the connecting plate is arranged between the evaporator and the electronic expansion valve, the heat dissipation bridge is arranged at one side of the connecting plate close to the electronic expansion valve, and the heat dissipation bridge and the connecting plate are integrally formed or are fixedly connected.
Preferably, the side of the connecting plate close to the evaporator is in direct contact with the evaporator.
Preferably, the side of the connecting plate close to the evaporator and the evaporator are fixedly connected to be in direct contact with one another.
Preferably, the side of the connecting plate close to the evaporator is fixedly connected to the evaporator by welding, and a welding surface is an entire contacting surface between the connecting plate and the evaporator, or a contacting surface between the evaporator and a position, corresponding to the heat dissipation bridge, at the side of the connecting plate close to the evaporator.
Preferably, the bracket further includes a base, the base is horizontally arranged at a bottom of the connecting plate, the connecting plate and the base are integrally formed or are fixedly connected, the base is fixedly mounted in automobile, and the evaporator and the electronic expansion valve are, respectively, located at two sides above the base.
Preferably, the evaporator is directly fixed on one side of an upper surface of the base, and the valve body of the electronic expansion valve is directly fixed on the other side of the upper surface of the base.
Preferably, the bracket further includes a first supporting board, the first supporting board is fixedly mounted on the side of the connecting plate close to the evaporator, and the evaporator is fixedly mounted on the first supporting board.
Preferably, the bracket further includes a second supporting board, the second supporting board is fixedly mounted on the side of the connecting plate close to the electronic expansion valve, and the valve body of the electronic expansion valve is fixedly mounted on the second supporting board.
The automobile air-conditioning system according to the present application has the following beneficial effects.
1) In the automobile air-conditioning system according to the present application, heat quantity from the electronic expansion valve may be rapidly transmitted to the evaporator via the heat dissipation bridge and the cooling ring, and the refrigerating capacity of the evaporator is effectively utilized to cool the electronic expansion valve, thereby effectively utilizing a cold source and reducing an energy waste. Further the level of the temperature resistance of the electronic expansion valve is not required to be improved, thereby saving cost and avoiding a valve failure caused when the electronic expansion valve is working under a nonstandard working condition.
2) The automobile air-conditioning system according to the present application further includes a cooling ring having a gap, and two ends of the gap are fixedly connected, such that the cooling ring and the electronic expansion valve are abutted against each other more tightly, thereby improving the heat transfer efficiency of the cooling ring.
3) The automobile air-conditioning system according to the present application further includes a cover arranged at the top of the coil and connected to the cooling ring so as to enclose the coil and further improving the heat transfer efficiency between the electronic expansion valve and the evaporator.
4) The automobile air-conditioning system according to the present application further includes a connecting plate arranged between the electronic expansion valve and the evaporator so as to improve the heat transfer efficiency between the electronic expansion valve and the evaporator.
5) In the automobile air-conditioning system according to the present application, the electronic expansion valve and the evaporator are fixedly mounted on the bracket, thereby further enhancing the overall structural strength of the automobile air conditioner.
6) In the automobile air-conditioning system according to the present application, the electronic expansion valve is fixedly mounted next to the evaporator, which realizes a well cooperation between the evaporator and the electronic expansion valve, shortens a connection pipeline between the evaporator and the electronic expansion valve, and enhances the capability of vibration resistance; and meanwhile the automobile air-conditioning system has a compact structure, the using space of the automobile air conditioner is effectively saved, and the overall structural strength of the automobile air-conditioning system is enhanced.
7) The structural design philosophy of fixedly mounting the electronic expansion valve next to the evaporator via a bracket to make the coil of the electronic expansion valve work under a standard working condition in the automobile air-conditioning system according to the present application may be applied in a traditional refrigerating system to provide a basis for realizing a comprehensive utilization of the energy of the refrigerating system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an automobile air-conditioning system according to an embodiment of the present application;
FIG. 2 is a left view of the automobile air-conditioning system of the embodiment shown in FIG. 1 ;
FIG. 3 is a left view of an automobile air-conditioning system according to another embodiment of the present application;
FIG. 4 is a left view of an automobile air-conditioning system according to another embodiment of the present application;
FIG. 5 is a left view of an automobile air-conditioning system according to another embodiment of the present application;
FIG. 6 is a perspective view of an automobile air-conditioning system according to another embodiment of the present application;
FIG. 7 is a perspective view of a bracket of an automobile air-conditioning system according to another embodiment of the present application;
FIG. 8 is a perspective view of a bracket of an automobile air-conditioning system according to another embodiment of the present application;
FIG. 9 is a perspective view of a bracket of an automobile air-conditioning system according to another embodiment of the present application;
FIG. 10 is a top view of the bracket of the embodiment shown in FIG. 1 ;
FIG. 11 is a rear view of the bracket of the embodiment shown in FIG. 1 ;
FIG. 12 is a diagram showing highest temperatures of a cooling ring of the embodiment shown in FIG. 1 in a first thermal test; and
FIG. 13 is a diagram showing highest temperatures of the cooling ring of the embodiment shown in FIG. 1 in a second thermal test.
DETAILED DESCRIPTION
In the automobile air-conditioning system according to the present application, heat from an electronic expansion valve is rapidly transferred to an evaporator through a bracket having a heat dissipation bridge and a cooling ring, and the refrigerating capacity of the evaporator is effectively utilized to cool the electronic expansion valve, thereby effectively utilizing a cold source and reducing an energy waste. Further the level of the temperature resistance of the electronic expansion valve is not required to be improved, thereby saving cost and avoiding a valve failure caused when the electronic expansion valve is working under a nonstandard working condition. Embodiments of an automobile air-conditioning system of the present application will be described in detail hereinafter in conjunction with the drawings.
Reference is made to FIG. 1 , which is a perspective view of an automobile air-conditioning system according to an embodiment of the present application. The automobile air-conditioning system includes an evaporator 1 and an electronic expansion valve 2 which are communicated with each other via a pipe, the electronic expansion valve 2 includes a coil 200 and a valve body 201 , and the coil 200 is fixedly mounted on the valve body 201 . The automobile air-conditioning system further includes a bracket 3 , and the bracket 3 includes a base 300 , a connecting plate 301 , a heat dissipation bridge 303 and a cooling ring 302 .
The evaporator 1 and the electronic expansion valve 2 are respectively arranged at two sides of the connecting plate 301 , and the evaporator 1 is in direct contact with the connecting plate 301 . Further, the evaporator 1 and the connecting plate 301 are fixedly connected to be in direct contact with one another. Contacting surfaces of the evaporator 1 and the connecting plate 301 may be fixedly connected by partially welding or wholly welding. As shown in FIG. 2 , which is a left view of the automobile air-conditioning system of the embodiment shown in FIG. 1 , the contacting surfaces of the connecting plate 301 and the evaporator 1 are connected by wholly welding.
The heat dissipation bridge 303 is arranged at a top of the connecting plate 301 at a side close to the electronic expansion valve 2 , and the heat dissipation bridge 303 and the connecting plate 301 are fixedly connected or are formed integrally. It can be appreciated for those skilled in the art that, the heat dissipation bridge 303 may be arranged at any position on the connecting plate 301 at the side close to the electronic expansion valve 2 .
The cooling ring 302 is of an annular structure, and the cooling ring 302 and the heat dissipation bridge 303 are fixedly connected or are formed integrally. The coil 200 of the electronic expansion valve 2 is arranged inside the cooling ring 302 and is surrounded by the cooling ring 302 , wherein the coil 200 is in direct contact with the cooling ring 302 . Further, the coil 200 and the cooling ring 302 are fixedly connected to be in direct contact with one another. In a case that the coil 200 is in direct contact with the cooling ring 302 but is not fixedly connected to the cooling ring 302 , the valve body 201 and the connecting plate 301 are fixedly connected to fixedly connect the electronic expansion valve 2 to the connecting plate 301 . In a case that the coil 200 and the cooling ring 302 are fixedly connected, the valve body 201 and the connecting plate 301 may be in direct contact with one another without being fixedly connected, or be arranged with a gap therebetween, or be fixedly connected.
The side of the heat dissipation bridge 303 close to the evaporator 1 is in direct contact with the evaporator 1 , and the coil 200 is in direct contact with the cooling ring 302 , thus heat generated by the coil 200 of the electronic expansion valve 2 may be transmitted to the evaporator 1 via the heat dissipation bridge 303 and the coil 200 .
Further, the heat dissipation bridge 303 and the evaporator 1 are fixedly connected, and the coil 200 and the cooling ring 302 are fixedly connected, thereby not only improving a heat transfer efficiency between the electronic expansion valve 2 and the evaporator 1 , but also making the structure of the automobile air-conditioning system more compact and improving the overall structural strength of the automobile air-conditioning system.
The base 300 is horizontally arranged at a bottom of the connecting plate 301 , and the evaporator 1 and the electronic expansion valve 2 are, respectively, arranged at two sides above the base 300 . The base 300 is fixedly mounted on the automobile, and the connecting plate 301 and the base 300 are integrally formed, or the connecting plate 301 and the base 300 are formed separately and the connecting plate 301 is fixedly mounted on the base 300 .
In the above embodiments, the electronic expansion valve 2 is fixedly mounted on the bracket 3 , and the bracket 3 is fixedly mounted in the automobile and is fixedly connected to the evaporator 1 .
Further, the cooling ring 302 is fixedly mounted on the connecting plate 301 via the heat dissipation bridge 303 , and the coil 200 of the electronic expansion valve 2 is fixedly mounted in the cooling ring 302 . In this embodiment, the cooling ring 302 is of a complete annular structure. The connecting plate 301 , the cooling ring 302 and the heat dissipation bridge 303 are formed integrally. Alternatively, the connecting plate 301 , the cooling ring 302 and the heat dissipation bridge 303 may be formed separately.
According to another embodiment of the present application, the bracket 3 may only include the heat dissipation bridge 303 , and the heat dissipation bridge 303 is arranged between the evaporator 1 and the electronic expansion valve 2 . The electronic expansion valve 2 is in contact with the evaporator 1 via the heat dissipation bridge 303 to transmit heat. Further, the coil 200 of the electronic expansion valve 2 is in contact with the evaporator 1 via the heat dissipation bridge 303 to transmit heat.
Reference is made to FIG. 3 , which is a left view of an automobile air-conditioning system according to another embodiment of the present application. The bracket 3 may only include the heat dissipation bridge 303 and the cooling ring 302 , and the heat dissipation bridge 303 and the cooling ring 302 are arranged between the evaporator 1 and the electronic expansion valve 2 . The heat dissipation bridge 303 has one side in contact with the evaporator 1 and the other side connected with the cooling ring 302 having a gap. The electronic expansion valve 2 is in contact with the cooling ring 302 and transmits heat to the evaporator 1 via the cooling ring 302 and the heat dissipation bridge 303 .
The heat dissipation bridge 303 has one side fixedly connected to the evaporator 1 and the other side fixedly connected to the cooling ring 302 having the gap, and the electronic expansion valve 2 is fixedly mounted on the cooling ring 302 . The coil 200 of the electronic expansion valve 2 is fixedly mounted inside the cooling ring 302 , such that heat from the coil 200 of the electronic expansion valve 2 may be transmitted to the evaporator 1 via the cooling ring 302 and the heat dissipation bridge 303 .
The heat dissipation bridge 303 and the cooling ring 302 may be formed integrally or separately. In a case that the heat dissipation bridge 303 and the cooling ring 302 are formed separately, the heat dissipation bridge 303 and the cooling ring 302 are fixedly connected, and the fixed connection may be realized by welding, threaded connection, clamping connection and etc. The evaporator 1 is directly fixed on the automobile, and the electronic expansion valve 2 is fixedly connected to the evaporator 1 via the cooling ring 302 and the heat dissipation bridge 303 , thereby making the structure of the automobile air-conditioning system more compact.
Unlike the embodiment in FIG. 1 , in this embodiment, the coil 200 and the cooling ring 302 are fixedly connected, the heat dissipation bridge 303 and the evaporator 1 are fixedly connected, and the evaporator 1 is directly mounted in the automobile, thereby shortening the connecting pipe between the evaporator 1 and the electronic expansion valve 2 , enhancing the vibration resistance, and meanwhile making the structure of the automobile air-conditioning system compact, effectively saving the usage space of the automobile air conditioner, and improving the overall structural strength of the automobile air conditioner.
According to another embodiment of the present application, the bracket 3 may only include the heat dissipation bridge 303 , the cooling ring 302 and the connecting plate 301 . Reference is made to FIG. 4 , which is a left view of an automobile air-conditioning system according to the embodiment of the present application. The evaporator 1 is fixedly mounted in the automobile in practical use, and the connecting plate 301 has one plane in direct contact with the evaporator 1 and another plane fixedly arranged with the electronic expansion valve. Contacting planes of the connecting plate 301 and the evaporator 1 may also be partially welded.
Reference is made to FIG. 5 , which is a left view of an automobile air-conditioning system according to another embodiment of the present application. Unlike the embodiment shown in FIG. 1 , in this embodiment, besides the heat dissipation bridge 303 , the cooling ring 302 and the connecting plate 301 , the bracket 3 further includes a first supporting board 304 and a second supporting board 305 which are respectively mounted on two planes at two sides of the connecting plate.
The first supporting board 304 is fixedly mounted at the side of the connecting plate 301 close to the evaporator 1 and is located below the evaporator 1 , and the evaporator 1 is fixedly mounted on the first supporting board 304 .
The second supporting board 305 is fixedly mounted at the side of the connecting plate 301 close to the electronic expansion valve 2 and is located below the cooling ring 302 , and the valve body 201 of the electronic expansion valve 2 is fixedly mounted on the second supporting board 305 .
Other structures of the present embodiment are the same as the first embodiment. In this embodiment, the connecting plate 301 and the evaporator 1 may be in direct contact with one another, or the contacting surfaces thereof may be wholly welded. Only one of the first supporting board 304 and the second supporting board 305 may be mounted, for example, in a case that the first supporting board 304 is not provided, the connecting plate 301 and the evaporator 1 may be directly connected by welding; and similarly, in a case that the second supporting board 305 is not provided, the connecting plate 301 and the electronic expansion valve 2 may be directly connected by welding.
The connecting plate 301 , the first supporting board 304 and the second supporting board 305 may not only strengthen the automobile air-conditioning system, but also accelerate the heat transfer between the electronic expansion valve 2 and the evaporator 1 .
Reference is made to FIG. 6 , which is a perspective view of an automobile air-conditioning system according to another embodiment of the present application. Unlike the embodiment shown in FIG. 5 , in this embodiment, the connecting plate 301 and the evaporator 1 are partially welded or are in contact with one another partially, for example, the side of the connecting plate 301 close to the evaporator 1 is welded to the evaporator 1 at a position corresponding to the heat dissipation bridge 303 .
Reference is made to FIG. 7 , which is a perspective view of the bracket according to another embodiment of an automobile air-conditioning system in the present application. To strengthen the cooling effect, a cover 307 having an opening may be further arranged on the cooling ring 302 at the top of the coil 200 to enclose the coil 200 , and the cover 307 is connected to the cooling ring 302 . The cover 307 on the cooling ring 302 may be sealed or may have an opening.
Reference is made to FIG. 8 , which is a perspective view of the bracket according to another embodiment of an automobile air-conditioning system in the present application. The cooling ring 302 has a gap, and such cooling ring 302 having the gap may facilitate the installation of the electronic expansion valve.
Reference is made to FIG. 9 , which is a perspective view of the bracket according to another embodiment of an automobile air-conditioning system in the present application. Two ends of the gap of the cooling ring 302 are fixedly connected. In this embodiment, the cooling ring 302 having the gap includes two connecting ends 306 , the two connecting ends 306 are two ring body extending portions extending outwardly from end portions of the ring body at the gap and arranged opposite to each other, and the two connecting ends 306 are fixedly connected via a bolt. Such cooling ring 302 having the gap may facilitate the installation of the electronic expansion valve 2 , and the electronic expansion valve 2 may be mounted more firmly. Since the two ends of the gap of the cooling ring 302 are fixedly connected, the cooling ring and the electronic expansion valve are abutted against each other more tightly, thereby improving the heat transfer efficiency of the cooling ring. The connection manner of the cooling ring 302 in this embodiment is simply an exemplary embodiment, and specific connection manner is not limited to the present embodiment.
In the above embodiments, each of the heat dissipation bridge, the cooling ring, the connecting plate, the base, the first supporting board and the second supporting board is made of heat conduction materials, and is preferably metallic material.
The operating principle of the above embodiments is as follows. When the refrigerating system is working, a surface temperature of the evaporator 1 is a constant low temperature, while the coil 200 of the electronic expansion valve 2 generates heat in operation, and when in summer or under a working environment of high temperature region, the temperature of the electronic expansion valve 2 is very likely to exceed a temperature resistance standard of 120 degree Celsius. A heat dissipation bridge 303 is provided between the evaporator 1 and the electronic expansion valve 2 , such that the heat from the electronic expansion valve 2 may be transmitted to the evaporator 1 via the cooling ring 302 and the heat dissipation bridge 303 , thereby realizing a cooling effect. Since the heat dissipation bridge 303 is in contact with the evaporator 1 , the heat dissipation bridge 303 is cooled by the evaporator 1 , thereby further cooling the cooling ring 302 , and then heat transfer occurs between the cooling ring 302 and the coil 300 to cool the electronic expansion valve 2 . In the present application, the cooling ring 302 and the heat dissipation bridge 303 function to transfer heat and fix the system structure.
Thermal analysis validation is conducted as follows.
In order to verify the actual using effect of the present application, a thermal analysis validation is conducted on the automobile air conditioner according to the embodiment of the present application shown in FIG. 1 . The heat dissipation bridge and the cooling ring in each solution in the following experiments are parts made of aluminum alloy material.
First Experiment: a comparison validation between the prior art and the embodiment of the present application shown in FIG. 1
The extreme heat-resistance temperature of the electronic expansion valve in this experiment is set as 120 degree Celsius, and other data are shown in Sheet 1.
Sheet 1
Type of analysis
Steady state thermal analysis
Material
Aluminum alloy
Environment temperature
120 degree Celsius
Unit
m
Temperature of a heat
2 degree Celsius
exchanger
Heat quantity of the
7 W
electronic expansion valve
Load
Convection: a vertical convective heat
transfer coefficient is 5.7 w/m 2 gk, and
a horizontal convective heat transfer
coefficient is 6.15 w/m 2 gk
Thermal load: a surface temperature of the
evaporator is 2 degree Celsius
Internal heat source: 286720.734 w/m 3
A comparison experiment is conducted under the above experimental conditions, and according to the analysis result, the highest temperature of the electronic expansion valve in the prior art reaches around 218 degree Celsius when the evaporator is not provided for transmitting heat. And the temperature at the top of the coil of the electronic expansion valve is relatively higher, and the temperature at the bottom of the coil is relatively lower, the above situation is caused because heat generated by the coil in operation is absorbed from the bottom of the coil by the valve body, and there is no heat dissipation approach at the top of the coil.
The analysis result shows that the solution in the embodiment of the present application shown in FIG. 1 has a significant heat dissipation effect. The highest temperature of the electronic expansion valve is around 8 degree Celsius, the temperature field distribution of the valve body of the electronic expansion valve is even, and the temperature difference is about 0.5 degree Celsius, which will not affect the system operation.
In the solution of the embodiment of the present application shown in FIG. 1 , heat transfer may be controlled by designing and modifying dimensions of the heat dissipation bridge and the cooling ring. Main parameters influencing the heat transfer in the technical solution of the present application are a height of the cooling ring and a width of the heat dissipation bridge. As shown in FIG. 10 , which is a top view of the bracket of the embodiment shown in FIG. 1 , the heat dissipation bridge has a length a and a width b. As shown in FIG. 11 , which is a rear view of the bracket of the embodiment shown in FIG. 1 , the cooling ring is a height c. In the following solutions, the cooling ring is set to have the same thickness and diameter, the connecting plate is set to have the same dimension, a distance from a center of the cooling ring to the connecting plate is set be the same, and the same components in each solution has the same material. Thermal analysis validations are conducted, respectively, to analyze influences on the heat dissipation efficiency of the cooling ring caused by the width of the heat dissipation bridge and the height of the cooling ring.
Second Experiment: a comparison validation is conducted with different widths of the heat dissipation bridge in the embodiment oft he present application shown in FIG. 1 , wherein the cooling ring has the same dimension, and the height of the cooling ring is 0.015 m. The experimental condition is shown in Sheet 1 and Sheet 2. The width of the heat dissipation bridge in each solution is shown in Sheet 2.
Sheet 2
Experiment solution
The width of the heat dissipation bridge (m)
First Solution
0.015
Second Solution
0.02
Third Solution
0.026
Fourth Solution
0.032
The experimental results of the four solutions are shown in FIG. 12 . In the first solution, the width of the heat dissipation bridge is 0.015 m, and the maximum temperature of the cooling ring is about 8 degree Celsius, which may basically satisfy the cooling requirement of the electronic expansion valve. And as can be seen from FIG. 12 , the maximum temperature of the cooling ring decreases as the width of the heat dissipation bridge increases. That is, the larger the width of the heat dissipation bridge, the better the cooling effect.
Third Experiment: a comparison validation is conducted with different heights of the cooling ring in the embodiment of the present application shown in FIG. 1 , wherein the heat dissipation bridge in each solution has the same dimension, and the width of the heat dissipation bridge is 0.015 m. The experimental condition is shown in Sheet 1 and Sheet 3. The height of the cooling ring in each solution is shown in FIG. 3 .
Sheet 3
Experiment solution
the height of the cooling ring (m)
Fifth Solution
0.015
Sixth Solution
0.01
Seventh Solution
0.005
Eighth Solution
0.003
The experimental results of the four solutions are shown in FIG. 13 . In the eighth solution, the height of the cooling ring is 0.003 m, and the maximum temperature of the cooling ring is about 44 degree Celsius, which may basically satisfy the cooling requirement of the electronic expansion valve. As can be seen from FIG. 13 , the maximum temperature of the cooling ring increases as the height of the cooling ring decreases. That is, the larger the height of the cooling ring, the better the cooling effect.
As can be concluded from the above verification results, the automobile air-conditioning system in the present application may better solve the problem that the electronic expansion valve is difficult to meet the requirement for temperature resistance of the automobile environment.
The embodiments described hereinabove are only exemplary embodiments of the present application. It should be noted that, for the person skilled in the art, many modifications and improvements may be made to the present application without departing from the principle of the present application. The protection scope of the present application is defined by the accompanying claims.
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An automobile air-conditioning system is provided, which includes an evaporator and an electrical expansion valve in communication via pipes, with the electrical expansion valve including a coil and a valve body, the coil being fixedly mounted on the valve body; the system also includes a support, the support including a heat-sinking bridge and a cooling ring, with the evaporator provided on one side of the heat-sinking bridge and the cooling ring provided on the other side of the heat-sinking bridge; the heat-sinking bridge and the cooling ring are formed in one piece or are connected with each other fixedly, and the coil is provided within the cooling ring. The automobile air-conditioning system has the advantages of a compact structural design, is capable of effectively cooling the electrical expansion valve, and has high system strength, stable transmission of coolant, and high security.
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BACKGROUND OF THE INVENTION
The invention relates to an internal combustion engine with spark ignition and at least one reciprocating piston, with an ignition device arranged in the zone of the cylinder axis and at least one fuel introduction device per cylinder for direct fuel introduction into the combustion chamber, which is limited by a roof-shaped combustion chamber cover surface of a cylinder head and the piston surface, from a radial position of the cylinder in the direction of the centre of the cylinder, and with at least one inlet conduit opening into the combustion chamber and producing a swirling flow in the combustion chamber, with the piston comprising a surface with an asymmetrical piston depression deflecting at least a portion of the injected fuel in the direction towards the ignition device.
DESCRIPTION OF THE PRIOR ART
Continuously rising demands placed on fuel consumption and the reduction of the exhaust gas emissions, and hydrocarbons in particular, require the use of new technologies in the field of internal combustion engines. As a result of currently common use of an external formation of mixture in Otto engines such as by using a suction pipe injection or a carburettor, a portion of the mixture sucked into the combustion chamber and cylinder during the valve crossover phase when the outlet and inlet valve are simultaneously open flows into the exhaust section of the internal combustion engine. A far from inconsiderable part of the measurable uncombusted hydrocarbons in the exhaust section also originates from mixture particles which are situated during the combustion in annular gaps or regions close to the wall where no combustion occurs. In addition to these aforementioned points, there is the required homogenization of the cylinder loading at an approximately stoichiometric mixture ratio of fuel and air which ensures a secure and misfire-free combustion. This requires a control of the engine load with the help of a throttle member for limiting the total mixture quantity that is taken in (quantity control).
This throttling of the suction flow leads to a thermodynamical loss which increases the fuel consumption of the internal combustion engine. The potential for the reduction of the consumption of the internal combustion engine can be estimated with approx. 20% by circumventing this throttling.
In order to avoid or reduce these disadvantages efforts have been made for a long time to operate spark-ignited internal combustion engines without throttling and to introduce the fuel only after ending the air intake within the combustion chamber and the cylinder, as in a self-igniting internal combustion engine.
From SAE 780699 a method is known in which the fuel is injected by means of a high-pressure injection nozzle directly into the combustion chamber of the internal combustion engine. The required time for the preparation of the mixture limits the temporal minimum distance between injection time and ignition time. A high pressure level is required for the injection process in order to obtain short injection times on the one hand and a favourable atomization of the fuel with respectively small spectrum of drops on the other hand. The preparation and dosing of the fuel occurs simultaneously. In order to obtain a merely only locally limited region with combustible fuel-air mixture it is necessary on the other hand to introduce the fuel only very late in the engine cycle (optionally only during the compression shortly before the ignition) in order to limit the time for the dispersion and dilution of the mixture in the combustion chamber air. The demand for sufficiently early injection for the purpose of complete fuel evaporation and the latest possible injection for maintaining the mixture layering are therefore in mutual opposition. It is thus the object of producing a locally limited mixture cloud from the injected fuel quantity, transporting the same from the orifice of the injection member to the vicinity of the ignition device and further mixing the mixture within the cloud with combustion chamber air. In this respect the following items are relevant:
The mixture cloud must remain clearly delimited particularly at low engine loads and should be located as far as possible in the centre of the combustion chamber for thermodynamical reasons and for reducing the emissions.
The mixture of the introduced fuel to an ignitable and preferably stoichiometric air ratio must occur in the short time interval between injection time and ignition time.
An important problem of such a combustion method lies in the cyclic fluctuations of the mixture forming process, i.e. the change of the sequence from one engine cycle to the next as a result of the turbulence of the flow processes in the suction system and cylinders of the internal combustion engine. In order to keep these fluctuations as small as possible, a form of flow should be produced in the cylinder which has a high stability and is maintained particularly during the compression phase of the engine cycle and does not change into random turbulent movements of flow.
This demand is fulfilled best by a swirling flow.
A swirling flow is understood as being the rotational flow in the cylinder which occurs in the known manner about an axis substantially parallel to the cylinder axis which is caused by the arrangement of the inlet conduit and the orifice of the inlet conduit(s) into the combustion chamber and cylinders of the internal combustion engine. During the compression there is only a slight change of the flow image, because the diameter of the vortex is not changed by the piston movement. Prior to the top dead center there is thus a stable rotational movement of the intaken air in the combustion chamber and cylinder.
The already mentioned cyclic fluctuations of the air ratio in the ignition region depend strongly on the distance of the injection nozzle from the ignition device and thus on the length of path which the injection jet has to cover up to the ignition device.
In addition to the reduction of the fluctuations by producing the most stable possible form of flow, the injection jet and the mixture cloud thus arising must be additionally guided by the combustion chamber geometry, which requires an at least partial wall application of the fuel by the injection jet. In order to ensure that this wall surface film of the fuel does not lead to increased formation of exhaust particulates and to delayed combustion, the inner flow of the cylinder must contribute to an intensive evaporation of this wall film and its convective transport to the ignition region.
Simultaneously, the combustion chamber surface, relating to the combustion chamber volume, should be kept as small as possible in order to limit wall heat losses particularly during homogenous operation.
From EP 0 694 682 A1 an internal combustion engine of the kind mentioned above with direct injection is known in which a swirling flow is produced in the cylinder chamber by shaping the inlet conduits. The piston surface is provided with a marked squeeze surface encompassing a piston depression, with the depression being eccentrically arranged in such a way that the ignition device being located centrally in the combustion chamber and the radially arranged injection valve are each located on the edge of the depression. The fuel is purposefully injected towards the floor of the depression moulded especially for this purpose. The piston surface therefore has the object of primarily deflecting the fuel jet. The swirling flow has the object of transporting the fuel deflected by the edge of the depression to the ignition device.
SUMMARY OF THE INVENTION
The object of the invention is the realization of a combustion method under the outlined boundary conditions on the basis of an inlet-generated swirling flow in the cylinder chamber of the internal combustion engine. It is intended to particularly achieve a stable operation over a wide range of the engine diagram.
This is achieved in accordance with the invention in that the piston depression is arranged with an arrangement tapering towards the edge of the piston and the edge of the piston depression is provided substantially with a U-shape as seen in the top view, that the depression floor changes in a continuously rising manner into the depression wall and that the piston surface encompassing the piston depression forms, as seen in the direction of the swirling flow, an expanding squeezing chamber at the top dead center of the piston in conjunction with the combustion chamber cover surface. As a result, the stable swirling flow is used to transport the injected fuel to the ignition device by using the piston geometry and to simultaneously improve the local preparation of the mixture. The piston depression is provided with a compact arrangement and is located approximately in the centre of the combustion chamber for the guidance of the injection jet and for controlling the stratified fuel-air mixture. The asymmetrical formation of the piston edge encompassing the depression supports the inflow of an oblique swirling flow into the region of the depression. The piston surface is arranged in such a way that the smallest possible surface-to-volume ratio is achieved. The swirling flow is supported during the upward movement of the piston by the squeezing chamber which increases in the direction of the swirling flow.
The swirling flow is guided into the region of the piston depression in particular if the piston surface consists in the direction of the rotating flow of three different, mutually successive angular sectors, with the surface in the first sector in the top dead center of the piston movement approaching the combustion chamber cover surface up to a residual distance which is preferably between 1 and 5 mm and extending substantially parallel to the same and the surface in the second sector dropping continuously up to a plane formed by the piston edge and the piston depression being substantially open towards the cylinder wall in the third sector. It is provided in detail that the first angular sector, measured in the direction of the swirling flow, encloses an angular range of approx. 70° to 120° about the cylinder axis, that the second angular sector encloses an angular range of approx. 130° to 200° about the cylinder axis and that the third angular sector encloses an angular range of approx. 60° to 160° about the cylinder axis. During the upward movement of piston an additional swirl leading to the piston is produced by the surface of the piston which is partly arranged as a squeezing surface, as a result of which the inner cylinder flow generated by the air inlet members of the internal combustion engine is accelerated during the compression phase and is guided to the ignition device by way of the surface used by the fuel jet.
It is preferably provided in this respect that the depression wall in the zone of the first and second angular sector is arranged in the zone of the upper edge with a deviation of a maximum of ±20° parallel to the cylinder axis. In order to keep the depression as compact as possible it is advantageous if, as seen in the direction of the cylinder, the smallest distance between the upper edge of the depression and the ignition device is a maximum of 0.3 times the piston diameter D. The ignition device is preferably arranged above the piston depression.
In a particularly preferred embodiment of the invention it is provided that the orifice of the fuel injection device is arranged in the combustion chamber wall on the cylinder head side at a distance from the cylinder axis of between 0.3 to 0.5 times the piston diameter D, with the central line of the injection jet to the cylinder axis or a straight line parallel to the cylinder axis being inclined at an angle of approx. 20° to 70° and, as seen in horizontal projection, being directed approximately radially into the combustion chamber. It is further provided that the injection jet impinges completely within the piston depression on the piston surface in at least one position of the piston. This allows for a particularly favourable concentration of the fuel vapour transported by the accelerated flow into a partial region of the combustion chamber volume.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is now explained in closer detail by reference to the figures, wherein:
FIG. 1 shows a cross section through a cylinder of an internal combustion engine in accordance with the invention pursuant to line I--I in FIG. 2;
FIG. 2 shows a cross section through said cylinder pursuant to line II--II in FIG. 1;
FIG. 3 shows a top view on the cylinder of FIG. 1 and 2;
FIG. 4 shows another embodiment of the invention in a top view on the cylinder;
FIGS. 5 and 6 show further embodiments of the invention with five valves per cylinder;
FIGS. 7 and 8 show further embodiments of the invention with three valves per cylinder;
FIG. 9 shows a further embodiment with two valves per cylinder in a top view and
FIG. 10 shows a spatial representation of the piston surface of the internal combustion engine in accordance with the invention.
Parts with the same function are provided in the embodiments with the same reference numerals.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A reciprocating piston 2 is arranged longitudinally movable in a cylinder 1 of an internal combustion engine. As a result of the roof-like combustion chamber cover surface 3 of the cylinder head 4 and the piston surface 5 of the piston 2 a combustion chamber 6 is formed into which one or several inlet conduits 7 and at least one outlet conduit 8 open by way of inlet valves 9 and outlet valves 10. An ignition device 21 is arranged in the zone of cylinder axis 1a, which device is formed by a spark plug. A fuel injection device 11 opens into the combustion chamber through the combustion chamber cover surface, with the orifice 15 being situated in the region of cylinder wall 1c.
The axis 11a of the fuel injection jet is provided with an angle α of 20° to 70° towards a straight line 1b which is parallel to the cylinder axis 1a. The orifice 15 of the fuel injection device 11 is located at a distance a of between 0.3 to 0.5 times the piston diameter D from the cylinder axis 1a.
A part of the piston surface 5 is arranged as a piston depression 12 tapering towards the piston edge 2a. The floor 12a of the piston depression 12 changes continuously into the depression wall 12b which in the region of the upper edge 12c of the depression 12 is arranged approximately in the direction of the cylinder axis 1a. The fuel injection device 11 is directed into the piston depression 12, so that as a result of the mixture of the injected fuel with the air entering the combustion chamber as a swirling flow 13 a mixture cloud 16 is obtained which as a result of the shape of the depression is guided in the direction of the ignition source 11, as is indicated schematically in FIG. 1.
The piston surface 5a encompassing the piston depression 12 consists, as seen in the direction of the entering swirling flow 13, of three different, mutually consecutive angular sectors A, B and C, as is shown in the FIGS. 3 to 9. The first sector A extends over an angular range of approx. 70° to 120°, starting in the region in which the upper edge 12c of the piston depression 12 tapers out into the piston floor 12a. The surface 5 of the piston 2 extends in the first sector approx. parallel to the combustion chamber cover surface 3 and approaches the combustion chamber cover surface 3 in the top dead centre of the piston 2 up to a residual distance of between 1 and 5 mm. The second sector B extends over an angular range of approx. 130° to 200° and is provided with the particularity that surface 5a of piston 2 which forms a squeezing surface sinks continuously up to the plane 2b as formed by the piston edge 2a. In the third sector C, which extends over an angular range of approx. 60 to 150° about the cylinder axis 1a, the piston depression 12 is substantially open towards the cylinder wall 1b. The central axis 11a of the injection jet is located, as seen in the axial direction of the cylinder, within said third sector C.
The arrangement of the surface of piston 2 in the sectors A, B and C causes that the inlet-generated swirling flow, which is indicated in FIGS. 3 to 10 with the reference numeral 13, is accelerated during the compression process and is guided over the surface of piston depression 12 which is moistened by the fuel jet to the ignition device 11. It is achieved simultaneously that the fuel conveyed by the accelerated flow 13 concentrates in a partial region of the combustion chamber 6.
The combustion chamber depression 12 and the ignition device 11 are preferably arranged in such a way that the smallest distance s between the upper edge 12c of depression 12 and the ignition device 11 is a maximum of 0.3 times the piston diameter D. The ignition device 11 is preferably located above the depression 12.
FIGS. 3 and 4 show embodiments with two inlet valves 9 and two outlet valves 10, with one inlet conduit 7 leading to each inlet valve 9. A conduit shut-off member 14 can be arranged in at least one inlet conduit 7. The fuel injection device 11 is arranged either between the two inlet ducts 7 (FIG. 3) or in the region between one inlet valve 9 and one outlet valve 10 (FIG. 4).
FIGS. 5 and 6 show embodiments in accordance with the invention with five valves, namely three inlet valves 9 and two outlet valves 10 per cylinder. Two of the three inlet conduits 7 leading to the inlet valves 9 can be provided with conduit shut-off members 14 in order to produce the desired swirling flow 13. The injection of the fuel can occur through the fuel injection device 11 between two inlet valves 9 (FIG. 5) or between one inlet valve 9 or an outlet valve 10 (FIG. 6).
FIGS. 7 and 8 show embodiments for internal combustion engines with three valves, namely two inlet valves 9 and an outlet valve 10 per cylinder 1. One of the two inlet conduits 7 leading to the inlet valves 9 is equipped with a conduit shut-off device 14 for producing the required swirling flow 13. The fuel injection can occur, in analogy to the embodiments as described above, by way of fuel injection device 11 which is arranged between two inlet valves 9 (FIG. 7) or between an inlet valve 9 and the outlet valve 10 (FIG. 8).
FIG. 9 shows a simple embodiment for internal combustion engines with an inlet valve 9 and an outlet valve 10 per cylinder 1. In this case too the inlet conduit 7 is arranged with a swirl-producing arrangement, so that during the filling of the cylinder and during the compression process a marked swirling flow 13 is obtained which is supported by the shape of the piston in accordance with the invention.
FIG. 10 shows a three-dimensional view of the piston surface 5 of piston 2 as arranged in accordance with the invention. During the compression process the swirling flow 13 is accelerated in the angular sector B and is guided in the angular sector C over the piston floor 12a which is moistened with fuel.The portion of the injected fuel which impinges on piston 2 is deflected in the direction towards the ignition device 21 and the fuel conveyed by the accelerated flow 13 is simultaneously concentrated in a partial region of combustion chamber 6.
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An internal combustion engine with spark ignition and a piston that includes a substantially U-shaped asymmetrical piston depression with a depression floor that tapers towards an edge of the piston and that changes in a continuously rising manner into a depression wall, and an expanding squeezing chamber, the arrangement being adapted to promoting a swirling rather than a turbulent flow of injected fuel.
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RELATED APPLICATIONS
[0001] This Application claims priority to U.S. Provisional Patent Application No. 60/521,718 filed on Jun. 24, 2004 titled “A METHOD TO CREATE BACKUP FILES ON REMOTE SYSTEMS OVER THE NET”, by Josef Ezra, which a claim to priority is made and is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates in general to backup and synchronization of data in a network, and more particularly to backup and synchronization of workstations to remote computers.
[0004] 2. Related Art
[0005] It is not uncommon these days for households and small businesses to have computer networks with workstations, printers, and servers, or simple pier-to-pier mesh networks of computers. Workstations are computers that typically have an operating system, application programs, and data files located on a local storage device, such as at least one of a hard disk drive, floppy disk drive, optical drive, tape drive, or memory drive. This local storage device typically has electromagnetic parts and/or electronics that are susceptible to failures due to use and age of the storage device. Similarly, these storage devices are also susceptible to environmental damage from fire, water, electrical surges, and static electricity.
[0006] When damage or failure in a storage device occurs, it is commonly called a “crash” as in “a hard drive crash.” Upon a “crash”, data contained in the storage device is often partially or totally damaged and unrecoverable. But on a workstation in a network, only locally stored data is affected and possibly unrecoverable. This is because data often resides on the server and is only accessed by the workstation. Often local data is work in progress or other personal files and notes that the user of the workstation has saved. For example, a workstation may access a database that resides on the server to generate reports. But, a local storage device crash on the workstations has little impact on the data stored at the server.
[0007] Current approaches to backing up or saving data located on the local storage device include using tape backups, removable media, or mirrored storage devices to name but a few. Problems that occur with tape backups and removable media is that backup of the data only occurs at predetermined intervals with an added cost of hardware and storage media. Often small businesses and households rely on these periodic manual backup devices. Further, errors may occur in the data stored on the removable media, such as digital tapes. A problem with mirrored storage devices is the added cost and the backed up data is still present on the workstation that is susceptible to environmental damage.
[0008] Therefore it can be seen, then, that there is a need in the art for an approach to backing up and synchronizing data stored locally on a workstation.
SUMMARY
[0009] Approaches consistent with the present invention provide files and subdirectories to be backed up and restored in a network making use of workstations and servers within the network. A workstation may have a client and/or backup server implemented in software. A controller assigns a client to a server and may function as a proxy for the server. The client has a database that contains a list of files and subdirectories that need to be backed up or restored and communicates across the network with a server where the backed-up files reside. The server also maintains a database of backed-up items that enables the client and server to periodically verity the all flies are update.
[0010] Other systems, methods, features and advantages of the invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE FIGURES
[0011] The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. In the figures, like reference numerals designate corresponding parts throughout the different views.
[0012] FIG. 1 is a network diagram of a workstation having data backed up and synchronized to a server.
[0013] FIG. 2 is a ladder diagram of messages between the workstation, server, and controller of FIG. 1 .
[0014] FIG. 3 is a flow diagram of backup and synchronization of local data in the network of FIG. 1 .
DETAILED DESCRIPTION
[0015] In FIG. 1 , a network diagram 100 of a workstation having data backed up and synchronized to a server is shown. The network is shown with a workstation 102 that is in signal communication with a server 106 and a controller 108 . The server 106 is also in signal communication with the controller 108 . The signal communication may be via TCP/IP over wired Ethernet in the current implementation. In other implementations, the signal communication may be via wired network protocols, wireless protocols (802.11b, 802.11g, Bluetooth, cellular standards, etc. . . . ), or a combination of wired and wireless protocols.
[0016] The workstation 102 is executing software that implements a client 104 where local data is located that needs to be backed-up from, for example a personal computer with an operating system such as WIDOWS XP or OS9. The server 106 is executing software 105 that implements a backup server. The server 106 may be a network device such as a computer executes operating system software, such as Linux OS, WINDOWS SERVER 2003, to name but a few. The backup server 105 is a repository for backed up files via the client 104 on workstation 102 . The controller 108 is software that is implemented on one or more computers 110 that may be workstations or servers, but correlates the communication between the client 104 at a workstation 102 and the server 106 . In other implementations, the client 104 may be implemented in software that resides on the workstations 102 and the server portion 105 may be implemented in software that resides on another workstations (not shown) in one or more networks. Similarly, a workstation such as 102 may execute client and server software for implementing both the client 104 and the backup server 105 to backup local files in one or more remote workstations and may also store files from that workstation and other remote computers in the network.
[0017] The client 104 on workstation 102 and the backup server 105 may login or access the controller 108 . The controller 108 identifies or registers the status of workstation 102 and server 105 as being online. In other words, the controller 108 maintains a list of servers connected by each client and the last connection timestamp, so the clients will be able to receive this information during restoration of local data from a server. The controller 108 communicates with the backup server 105 in order to notify the backup server 105 to listen and accept requests from the client 104 .
[0018] The client 104 at workstation 102 may then connect to server 106 and backup local data to the server. If a connection from the client 104 to server 106 is not possible, then the controller 108 or a proxy in the network identified by the controller may buffer packets and forward them to the server 106 via the signal communication link between the controller 110 and the server 106 . If no link is available, then the controller may buffer the local data from the workstation 102 until the backup server 105 becomes available. Thus, the controller 108 may function as a temporary server for workstation 102 and client 104 . In other implementations the controller 108 may designate another workstation or server in the network to be a proxy for backup server 105 . In another implementation where there are only a limited number of workstations and servers, such as in a home network, a user may configure the workstation 102 , client 104 , backup server 105 , and controller 108 manually.
[0019] The client 104 may have a database that represents a state of the local data that needs to be backed-up or stored at the backup server 105 . The client 104 monitors the database and file system of the workstation 102 and manages which local data (files and directories) is sent to the backup server 105 . The local data to be sent to the backup server 105 may be compressed using known compression algorithms and or encrypted to save space and as added security. In the current implementation, the local data is sent with the additional information of original file name, full path name, and last change timestamps.
[0020] Local data is received at the backup server 105 and stored in a dedicated storage space. The local data stored at the backup server 105 is identified in a database located at the server 106 with the additional information and the sender's identification. Older versions of the local data (i.e. files and directories) received at the backup server 105 may be deleted or otherwise removed from the server. In other implementations, different versions of the local data may reside and be retrieved from the backup server 105 .
[0021] Upon the database being updated with the additional information, the server 106 may send an acknowledgment message to the client 104 located on workstation 102 . When client 104 receives the acknowledgment message, the database maintained by the client is updated with the additional information. In other implementations, the additional information may already be in the database located at the client 104 and a flag or bit being set in response to the acknowledgment message.
[0022] The database located at the client 104 may contain information such as:
General data: Server ID General information: last connection timestamp Key: file/directory name Filter: wild characters and strings Time: last change timestamp of last successful save Encryption level: type of encryption
The “Server ID” is used to identify the backup server 105 in the network that is storing the local data from workstation 102 . The key is used to identify the file and directory. In other implementations, different types of identifies may be used. In addition to the key, a time filed is used to identify the version of the file/directory being stored.
[0029] The database maintained at the backup server 105 may contain the following information:
General data: Client ID General information: last connection timestamp Key: Original full filename Copy filename: filename on server ID number: A serial number allocated by server Last Change Timestamp: Last change timestamp of file stored on server.
The backup server 105 identifies the client 104 that the file is being received from with a client identifier (i.e. Client ID). The “Client ID” is stored in the database in addition to the time of communication with the client 104 . The time of communication with the client is stored as the “last connection timestamp” in the database of the backup server 105 . The original full file name is saved at the backup server 105 in order for the backup server 105 to rename files and received data, thus avoiding duplicate name issues. The Copy filename is the renamed file or data/pointer in a database, or any way that the backup server 105 may identify the client's data being stored at the backup server 105 . Further, the server may generate a serial number based on a counter or algorithm to identify the record in the database. The server is able to identify if local data received from the client 104 is newer than a file already stored in the database by use of the last change timestamp. Similarly, the last change timestamp is used to verify if an older version of a file is being requested in a restore request. In one implementation, the client 104 and/or backup server 105 identification may be the unique name used to log into the controller 108 , where the controller 108 provides the network identification of the client 104 , server 106 , and proxy when needed. In yet another implementation, the full filename may be encrypted by the client 104 with a unique key before being sent to the backup server 105 in order to increase security
[0036] The file monitoring process occurs in the client 104 at workstation 102 . The client accesses the database and iterates through the entries. If an entry in the database is associated with a file, the timestamp of the actual file is checked. If the timestamp is not defined or is older than the files “last change” timestamp in the database, then the local data, i.e. file, is sent to the backup server 105 . If a file is marked as “saved” does not exist on the client 104 (for example, after being erased by the user), a delete message may be sent to the backup server 105 from the client 104 according to a predefined policy. If for some reason, the local data cannot be sent, then reconnection to the server is attempted and the local data is sent again to the backup server 105 or cached at the controller 108 . In the current implementation, the file monitoring process may occur when the computer, such as workstation 102 and server 106 are not loaded (processor is not being heavily utilized).
[0037] If the entry in the database at the client 104 is associated with a directory, each of the file or subdirectory in the directory that matches the filter and does not already exist in the database is added to the database. New local data, i.e. files and subdirectories may inherit the parent's directory's encryption level and filter, or a default one. After processing all local data in the subdirectory (including the newly added items), the client 104 processes may become idle for a predetermined time. In other implementations, the process may become idle until a predetermined event occurs, such as the workstation being powered on or an application is closed.
[0038] If local data at the workstation 102 needs to be sent from the client 104 to the backup server 105 it is encrypted according to the encryption level. The client 104 may have the local data compressed and encrypted to a temporary buffer located at the workstation 102 . If the file is too big to be processed at the workstation 102 without affecting the workstation performance, the local data may be divided into multiple blocks with each block being processed.
[0039] When the backup server 105 receives the local data from the workstation 102 , it is saved in its own file system in a dedicated area under a file identifier selected by the server 102 . The database on the backup server 105 then is updated with the original file name, file identifier selected by the backup server 105 , and the last change timestamp. In other implementations, the backup server 105 may save the data in a local database, such as mysql, BerklyDB, or any key data type data-store/data-structure.
[0040] Turning to FIG. 2 , a ladder diagram 200 of messages between the client 104 , server 105 , and controller 108 of FIG. 1 is shown. The client 104 sends a “Request Server” message 202 to the controller 108 . The controller 108 response with a Request Server Response message 204 to the client 104 and an “Assign Server” message 206 to server 106 notifying the server 106 of the assignment of the client 104 .
[0041] The client 104 then may send local data via “Send Local Data” 208 message that contains the information about the local data being transferred. Upon completion of the local data being transferred from the workstation 102 to the backup server 105 , the server then sends a “Local Data Acknowledgment” message 210 . In some implementations, the “Send Local Data” message 208 may contain the actual local data being transferred from the client 104 to the backup server 105 .
[0042] If the workstation 102 requires a file to be restored, the client 104 sends a “Restore Local Data Request” message 212 to the server. The backup server 105 responds with a “Restore Local Data Response” message 214 and also transfers the local data requested by the client 104 . If the transfer fails, then the client 104 may request the local data again. After a predetermined number of attempts, the client will identify that the data will be unavailable. In another implementation, the backup server 105 may agree to send the data by a controller 108 acknowledging that the client 104 is in a ‘recover mode’ and restoring data.
[0043] In FIG. 3 , a flow diagram 300 of backup and synchronization of local data in the network of FIG. 1 is illustrated. The process starts 302 on a client 104 with the client 104 accessing the database and identifying items 304 . If the item identified in step 0 . 304 is a directory 306 then each file or subdirectory in the directory 308 is check if it exists in the database 310 in the client 104 . If it exist 312 , then the next item is checked 308 .
[0044] If the identified item is not a directory 306 then the time stamp is checked. If the time stamp of the item is greater than or equal to the last change time stamp 314 then the next item is retrieved 316 . Otherwise, the local data (i.e. file) is sent to the server 318 . If an acknowledgment is received from the server, then the transfer was successful 320 and the time stamp is set to the last change time stamp 322 and the next item is identified 304 . If the local data was not successfully transferred in step 320 , then recovery from the failure 324 is attempted and the local data is sent 318 again.
[0045] In step 310 a file or subdirectory does not exist, then a check is made to determine if it matches a filter that is associated with this subdirectory 326 . If the file or subdirectory does match the filter 326 , then it is added to the database 328 at the client 104 and the next file or subdirectory is check 312 . Otherwise, the next file or subdirectory is checked 312 .
[0046] If all items in the database at the client 104 have been checked 316 then a delay or wait period for a predetermined (i.e. “X” seconds) 330 is made. After delay 330 , the database is again accessed and items in the database are synchronized 304 . In other implementations, the delay period may vary according to system (i.e. computer) or network load and a predetermined priority of the file/directory being checked. In yet other implementations, steps may be eliminated and/or combined if the system supports interrupts or callbacks hooked to a file changes. In such cases, there may only be a single iteration to check the files/directory status and create those hooks.
[0047] The flow diagram may be implemented in software or hardware or a combination of software and hardware. The software may be presented on a signal-bearing medium that contains machine-readable instructions such as magnetic tape, compact disc, paper punch cards, smart cards, or other optical, magnetic, or electrical digital storage device.
[0048] The foregoing description of an implementation has been presented for purposes of illustration and description. It is not exhaustive and does not limit the claimed inventions to the precise form disclosed. Modifications and variations are possible in light of the above description or may be acquired from practicing the invention. For example, the described implementation includes software but the invention may be implemented as a combination of hardware and software or in hardware alone. Note also that the implementation may vary between systems. The claims and their equivalents define the scope of the invention.
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An approach to archiving data that enables a client to back-up files to a server that is assigned by a client and periodically verify the most recent versions of the files are present on the server or restore backed-up files from the server to a workstations where a client resides.
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This application is a continuation of co-pending application Ser. No. 07/410,157, filed Sep. 20, 1989, now abandoned, which was a continuation-in-part of application Ser. No. 07/117,356, filed Oct. 27, 1987, now abandoned, which was itself a continuation-in-part of application Ser. No. 06/827,781, filed Feb. 7, 1986, now abandoned.
FIELD OF THE INVENTION
The present invention relates to apparatus for dispensing quantities of fluid from a container, and in particular to apparatus for accurately dispensing measured amounts of a liquid from a closed container of that liquid.
BACKGROUND OF THE INVENTION
There has been a long felt need for a simple, inexpensive and accurate device for dispensing a predetermined amount of fluid directly from a reservoir of that fluid without the need for separate measuring devices such as cups and/or measuring spoons. This need has existed, with varying requirements as to accuracy and service conditions, in such widely varying applications as dispensing of cough syrups, liquid soaps, detergents, antacids, traditional and veterinary medications, as well as the accurate dispensing of fluid components for various formula in research and development laboratories and hospitals.
A particularly advantageous application of such a device would be in the dispensing of both ethical and over-the-counter liquid medications. Although the dispensing of such medications does not, in many cases, require an analytical degree of accuracy and reproducibility, the usual approach of "teaspoon measurement" leaves much to be desired. For example, due to the many varied designs and capacities of teaspoons, a "one teaspoon" measurement could vary from 4 to 7.5 ml. In addition, an appreciable error can be introduced in the measuring process by the individual making the measurement; for example, an individual may habitually undercut the measurement to avoid spillage, whereas another individual may actually take a "heaping teaspoonful" in order to ensure good measure. It follows that, as the number of teaspoons required for the desired dosage increases, this margin of error is compounded. With regard to tablespoon measurement an even wider variance is encountered, and the actual quantity of medication administered could be anywhere from 12 to 24 ml. depending on the particular spoon used and the individual measuring the dosage. Also, when the particular medication is to be mixed with water or other liquid, the separate measuring device not only represents a possible source of inaccurate measurement but also a serious source of possible bacterial or viral contamination.
Another use for such a device would be in measuring and administering medication to individuals suffering from handicaps, neuromuscular disorders or debilitating diseases such as, for example, multiple sclerosis, Parkinson's disease, blindness or other condition where dispensing and/or administering the liquid medication utilizing a spoon or cup would be difficult or impossible. Currently, when the individual for whom medication is prescribed is, for instance, blind or has poor eyesight he must rely on supervisory personnel to dispense an accurate dosage. In the alternative, he can use a "braille" cup having raised annular rings formed in the sidewalls thereof to indicate the various dosages. Measurement using this device is accomplished by placing a finger within the cup at the appropriate ring representing the correct dosage and pouring the medication into the cup until the fluid level reaches the finger. The drawbacks of these methods are readily apparent. Full or part-time supervisory personnel are becoming increasingly expensive and the "braille" cup method is prone to potentially life-threatening inaccuracies.
In the field of veterinary medicine, there has also been a long felt need for measuring and dispensing apparatus capable of accurately and efficiently administering fluid medication to animals. To date this procedure has been accomplished through the use of tubes and eyedroppers wherein the veterinarian or owner would draw the correct dosage into the eyedropper or tube, insert the spout into the animal's mouth and expel the fluid. This method generates problems in that, should the animal fail to swallow the medication, a second application would be required. Further, repeated contact between the animal's mouth and the eyedropper, and then the eyedropper and the reservoir of medication, results in potentially dangerous contamination to the medication remaining in the reservoir.
Many devices have been proposed for the dispensing of controlled-volume increments of fluids from containers, but all have suffered from one or more of a number of disadvantages. For example, many of the proposed devices which operate by means of pressurizing the container holding the fluid have been prone to inaccuracy and erratic operation brought about by pressure differences between the ambient atmosphere and the vapor space over the fluid inside the device. Designs of this type tend to create a partial vacuum inside the container caused either by fluctuations in the ambient temperature and pressure or by altitude differences between the point where the dispenser is first joined to the container and the point of use. The partial vacuum could also be created by repeated withdrawals of fluid from the device without replacing the volume thus lost with an equivalent volume of air. This pressure differential tends to impede the flow of fluid out of the dispenser, resulting in dispensing of inaccurate dosages. By the same logic, an excess pressure in the apparatus will tend to promote an undesirably large outflow of the fluid causing an overdose or spillage.
This difficulty does not arise when the container is opened to the atmosphere to dispense a measured dosage with each use. However, when the container itself is opened directly to the atmosphere there is the attendant danger of spillage and/or contamination.
Devices which do not require opening for each use generally effect pressure equalization by allowing air to bubble into the reservoir of liquid medication simultaneously with the withdrawal of liquid therefrom. Heretofore this method required that the dispenser construction be rather complex to allow for the measured dispensing of the liquid and simultaneous pressure equalization. Some of these devices even made use of differential air pressure to control the flow of liquid and thereby cut off the flow at a desired volume. Such devices, however, require sophisticated and expensive mechanical construction.
While the foregoing description of the background of the invention has been directed primarily in terms of measuring and dispensing of medication, it will be recognized that the same considerations apply, with varying degrees of emphasis, to a wide variety of other applications.
OBJECTS AND STATEMENT OF THE INVENTION
It is therefore an object of the present invention to provide an improved means for measuring and dispensing predetermined quantities of fluid from a reservoir of that fluid.
Another object is to provide measuring and dispensing apparatus having improved accuracy and reproducibility with respect to the volume dispensed.
Still another object is to provide a measuring and dispensing means which is capable of adjustment in a simple and convenient manner, to dispense a pre-selected and variable volume of fluid.
A further object of the present invention is to provide means for measuring and dispensing predetermined quantities of liquid from an attached reservoir. This means for conducting the fluid preferably extends from the base of the chamber to about one-half the height of that chamber. This design feature permits the chamber to consistently retain and dispense correct measured dosages. This is because when the chamber is inverted, the chamber fills up until it reaches the top of the conduit. When the chamber is righted, a quantity of fluid must be present in the chamber which exceeds the height of the conduit thus permitting some overflow back into the reservoir.
If the conduit is too high, only a small portion of the fluid enters the chamber. When the chamber is righted, the fluid level may be below the top of the conduit thus preventing the chamber from retaining a consistent accurate measure.
The volume of the conduit structure itself also must be taken into account since it displaces fluid when the chamber is righted without the necessity for separate measuring devices.
Another object of the present invention is to provide a measuring means for a liquid wherein a surplus quantity of the liquid fed into the measuring chamber will be returned into the container thereby insuring an accurate and consistent measurement.
A particularly desirable object of the present invention is to provide a measuring and dispensing means in which the foregoing objects are provided by the use of a simple, inexpensive apparatus.
The present invention provides a unique and novel solution to the problem of accurately measuring and dispensing predetermined amounts of a liquid material from conventional flexible-wall containers. The invention comprises a device for dispensing a measured quantity of fluid from a supply of said fluid, the device including a container having at least one flexible wall and means for providing a measured amount of fluid for discharge from the device. This means is further adapted to fit the container and is provided with a chamber adapted to hold the measured amount of fluid to be dispensed. The device is also equipped with a means for conducting the fluid from the container to the chamber when the device is inverted and for conducting, when the device is righted, the amount of fluid in said chamber which is in excess of the measured amount back to the reservoir. The device is also provided with means for discharging the measured amount of fluid held in the chamber, this means including a conduit from a location within the chamber and proximate its base such that the fluid is discharged in response to a force exerted on the flexible wall of the container. Advantageously, the container will be formed from a resilient material such as is commonly employed to form so-called "squeeze bottles". The measuring means can be constructed of a clear or translucent glass or plastic and is provided with a connection between the measuring means and the container. Where desirable, the measuring means may be incorporated into the top of the container to prevent access to or contamination of the liquid in the reservoir.
Basically, the measuring means includes a dispensing means and comprises an integral unit preferably of rigid translucent plastic or glass. The measuring means is provided with a measuring chamber for receiving, measuring and maintaining the fluid to be dispensed. The walls of the chamber can be provided with annular rings or other markings thereon to indicate the desired dosage visually.
In operation, the container-measuring means combination is inverted allowing the fluid to enter the measuring chamber by means of a passage between the chamber and the fluid reservoir. The fluid is allowed to fill the chamber and, when the container is righted, excess fluid is automatically permitted to flow back into the reservoir leaving a predetermined dosage of the fluid within the chamber to be dispensed at will by the user.
The dispensing means, advantageously in the form of a long tube which extends from within the measuring chamber (typically from a location proximate the chamber's base) to some point outside the chamber, acts as a conduit for the measured fluid. Dispensing is accomplished by squeezing a flexible side-wall of the container thereby to increase the pressure within the measuring chamber and force the measured portion of the fluid in the chamber through the dispensing tube into an appropriate receptacle or other desired location. The dispensing tube can also be provided with a flexible joint to allow the dispensed fluid to be more easily directed into a glass, or where desirable, directly into the mouth of the patient. This feature obviates the need for any other measuring device such as a spoon or glass and thus avoids inaccurate measurements and spillage.
A closure or valve can be positioned within the dispensing tube to seal the reservoir and measuring chamber and prevent accidental spillage of any fluid therein. Where the device is to be used to dispense liquids to several different persons the dispensing tube may also be provided with disposable tips or sheaths to prevent contamination and/or the spread of disease.
A further refinement of this invention is the provision of means within the measuring chamber for varying the amount of liquid retained in the chamber once it is inverted and righted in sequence. This is accomplished, for example, by providing means for varying the height of the fluid retained within the measuring chamber and/or by varying the capacity of the measuring chamber to allow for different quantities of liquid to be retained within the measuring chamber.
Where the invention is to be used for fluids that are sugar-based or are particularly sticky, the chamber can be designed to be stored in the inverted position thus keeping the chamber full of fluid at all times. This prevents gumming up of the dispenser caused by drying up of the fluid in the chamber between uses.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of this invention will be apparent in the following detailed description of illustrative embodiments, especially when taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a perspective view showing one embodiment of the invention with the variable dose measuring chamber attached to a conventional squeeze bottle;
FIG. 2 is a horizontal cross-sectional view, taken along line 2--2 of FIG. 1, of the measuring chamber shown in FIG. 1;
FIG. 3 is a side elevational view, in cross-section, taken along line 3--3 of FIG. 2, of the measuring chamber and squeeze bottle shown in FIG. 1;
FIG. 4 is an exploded view, in perspective, of one embodiment of the inlet tubes of the measuring chamber;
FIG. 5 is a horizontal cross-sectional view, taken along line 5--5 of FIG. 4, of the outer inlet tube;
FIG. 6 is a side elevational view, in cross-section, of the variable dose measuring chamber shown in FIG. 3;
FIG. 7 is a perspective view, in section, of another embodiment of the invention providing a single predetermined dosage;
FIG. 8 is a side elevational view in cross-section, taken along line 8--8 of FIG. 7;
FIG. 9 is a horizontal cross-sectional view, taken along line 9--9 of FIG. 8 showing the single dosage embodiment of FIG. 7;
FIG. 10 is a perspective view, in section, of a variable dose embodiment of the invention;
FIG. 11 is a side elevational view in cross-section, taken along line 11--11 of FIG. 10 showing the slide and tube position for the adult dose in the embodiment of FIG. 10;
FIG. 12 is a side elevational view, in cross-section, showing the slide and tube position for closure of the chamber in the embodiment of FIG. 10;
FIG. 13 is a perspective view, in section, of another variable dose embodiment of the invention;
FIG. 14 is a side elevational view, in cross-section, taken along line 14--14 of FIG. 13, with the slide and tube in the adult dose position; and
FIG. 15 is a side elevational view, in cross-section, of the slide and tube of FIG. 14 in the closed position.
FIG. 16 is a side view of the invention incorporating two independent measuring chambers and reservoirs;
FIG. 17 is a top view through line I--I in FIG. 16 of the invention incorporating two independent measuring chambers and reservoirs.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings, and in particular to FIGS. 1-6, there is depicted an apparatus in with one embodiment of the present invention. The apparatus, denoted generally at 20, is mounted on the top of a conventional flexible-wall container 22 which container includes a mouth 24 having threads 26 provided circumferentially thereabout (see FIG. 3). Other forms of connection between the apparatus 20 and the container 22 are also suitable as circumstances dictate--e.g., a frictional insertion of the bottom of the apparatus into the top of a bottle in place of a cork or plastic stopper.
Enclosed within the apparatus 20 is a dosage measuring chamber 28 of cylindrical construction having a base portion 30 and a top portion 32. A passage 34 is formed in the base portion 30 of the chamber 28 to permit fluid 36 contained within the flexible-wall container 22 to pass between the dosage measuring chamber 28 and the flexible wall container 22. In this embodiment of the invention, this passage 34 opens into an inner tube 38 which is open at its distal and proximal ends. This inner tube 38 is provided with a plurality of vertical slots 40 of varying lengths (best shown in FIG. 4). The inner tube 38 is fixed to the base portion 30 of the dosage measuring chamber 28. An outer tube 42 is rotatably imposed over the inner tube 38 and adapted for movement between multiple positions. The outer tube 42 is provided with a plurality of vertical slots 44 which are at least of the same length as the longest slot in the inner tube 38. Preferably, these slots are positioned so that the bottom of the uppermost slot 40 is located about half the height of the inner tube 38. In this embodiment of the present invention the outer tube 42 is also provided with a knurled knob 46 fixed to the upper end of outer tube 42 to facilitate rotation of the outer tube.
The lower end of the outer tube has a series of notches 48 which engage protrusions 50 formed in the base portion 30 of the dosage measuring chamber 28. These notches 48 are positioned to engage protrusions 50 at points of alignment between vertical slots 40 in the inner tube 38 and vertical slots 44 in the outer tube 42. Optionally, notches 48 may be provided to engage protrusions 50 at points where the vertical slots 44 in the outer tube 42 do not align with the variable length vertical slots 40 in the inner tube, thus effectively sealing the dosage measuring chamber 28 from the fluid reservoir in the flexible wall container 22.
In this embodiment of the invention, sealing of the top of the dosage measuring chamber 28 is accomplished by providing knob 46 with an internal peripheral lip 52 which sealably engages a concentric notch 54 in the upper wall 56 of the dosage measuring chamber 28. This sealing may be further supplemented by interposing a seal 58 between the knob 46 and the top portion 32 of the dosage measuring chamber 28.
A discharge tube 60 is positioned within the dosage measuring chamber to provide a suitable conduit for the measured fluid 62 to be expelled from the dosage measuring chamber 28. The lower end 64 of the discharge tube 60 is advantageously provided with an angled opening 66 positioned in contact with or in close proximity to the base portion 30 of the dosage measuring chamber 28. This arrangement facilitates complete expulsion of the measured fluid through the exit tube and avoids the accumulation of excess fluid in the base of the chamber after dispensing is complete.
To measure a dosage of medication using the apparatus according to this embodiment of the invention, the knob 46 is first rotated until the vertical slots 44 in the outer tube 42 align with the appropriate vertical slots 40 in the inner tube 34 representing the desired dosage. This alignment may be accomplished by means of appropriate markings placed on the walls of the dosage measuring chamber and/or by forming the side walls 56 of the dosage measuring chamber 28 of a transparent or translucent material which permits visual confirmation of the appropriate alignment. Once slots 44 and 40 have been aligned, the chamber-container assembly, indicated generally at 68, is inverted permitting the fluid 36 contained in the reservoir to flow through passage 34 and aligned slots 40, 44 and fill the dosage measuring chamber 28. Subsequently, the assembly 68 is restored to its original upright position causing excess fluid in the dosage measuring chamber to drain back into the reservoir until the level of fluid 62 within the chamber reaches the bottom edge 70 of the inner slot 40. It is readily apparent to one skilled in the art that by varying the height of bottom edge 70 relative to the base portion 30 and/or by increasing the diameter of the chamber wall 56, a variable dosage may be maintained within the dosage measuring chamber 28.
After the assembly 68 is restored to its original upright position and the excess fluid has drained back into the reservoir 36, the liquid representing the desired dosage is maintained within the dosage measuring chamber 28 to await dispensing by the user. This dispensing is accomplished by compressing a flexible wall of container 22 thus creating a pressure differential between the fluid within the assembly 68 and the ambient environment. This pressure differential causes the expulsion of the measured fluid 62 through discharge tube 60; the discharging fluid can be directed as desired.
In certain embodiments of the invention, such as that depicted, the fluid contained within the reservoir may be sealed from the ambient conditions by rotating the outer tube 42 so that the vertical slots 44 are not aligned with any of the vertical slots in the inner tube 34. In this manner, the assembly may be stored or shipped in any attitude without the fear of leakage or contamination.
FIGS. 7-9 show a simplified embodiment of the present invention capable of measuring and dispensing a single predetermined dosage from a reservoir of fluid contained in a flexible-walled container. In this embodiment a simplified dosage measuring chamber is utilized (indicated generally at 70) which is mounted on the top of a conventional flexible-walled container 72. The attachment means between the chamber and the container 72 may be a threaded connection 74 as shown or any other type of engagement which provides an acceptable seal between the chamber and the container.
The chamber 70 is provided with an internally threaded lower portion 76 optionally provided with a plurality of vertical ridges in the external periphery thereof to aid in the removal of the chamber. Communication between the reservoir of fluid 78 in the flexible-wall container 72 and the chamber 70 is provided by an open-ended tube 80 of fixed length which extends through the base portion 82 of the flexible-wall container 72 into the chamber 70 for a predetermined distance. Preferably, this predetermined distance is about one-half the height of chamber 70. Sealing between the open-ended fixed length tube 80 and the container is provided by an annular shoulder 84 formed in the lower end of tube 80 which sealably abuts against the top lip 86 of the flexible-walled container 72 when the threaded engagement 74 is properly tightened.
A discharge tube 88 is positioned within the dosage measuring chamber 70 to provide a conduit for the measured dosage of the liquid 90 to a point outside the chamber. This tube 88 is optionally provided with an angled end 92 positioned in close proximity to the base portion 82 and extends to a point outside the dosage measuring chamber. In the embodiment shown in FIGS. 7-9 this tube 88 is angled at 94 to more easily direct the measured dosage to the desired location. Optionally, base portion 82 can be sloped downward toward end 92 to insure complete evacuation of the fluid in chamber 70. A valving means 93 may be positioned in a convenient location in the exit tube to seal the dosage measuring chamber 70 from ambient conditions. This may be desirable to avoid spillage or contamination.
To measure out a dosage of fluid utilizing this embodiment of the present invention, the valving means 94 is opened to vent the chamber and the chamber-container assembly 96 is inverted to permit fluid in the reservoir 78 to pass through the open-ended fixed length tube 80 and fill the dosage measuring chamber 70. Once this is accomplished, the assembly 96 is returned to its original upright position permitting any excess fluid located in the chamber 98 above the top edge 100 of the fixed length tube 80 to drain back into the container 72. Where the fluid to be dispensed is particularly viscous or where inlet tube 80 is narrow, a surface tension relieving means such as pin 101 can be formed adjacent the top edge 100 of tube 80 to break the surface tension and to initiate flow of the excess fluid back into the reservoir 78. The fluid remaining in the dosage measuring chamber 70 represents an accurate predetermined dosage 90 of the fluid.
In order to dispense the fluid within the chamber 70, pressure is applied to the flexible-walled container 72 creating a pressure differential between the inside of the chamber-container assembly 96 and the ambient conditions. As in previously described embodiments, this pressure differential forces the measured fluid 90 out of the chamber and through discharge tube 88. In both embodiments heretofore discussed pressure must be continuously applied to the flexible-walled container until the liquid contained in the dosage measuring chamber is totally expelled. After dispensing is complete the chamber of the embodiment shown in FIGS. 7-9 may be sealed by moving valving means 94 to a closed position.
Further embodiments of the present invention are shown in FIGS. 11-15. These embodiments show alternative means for measuring and dispensing variable doses of a fluid from a reservoir of that fluid maintained in a flexible-walled container.
Referring now to FIGS. 10-12, a variable dosage measuring chamber, indicated generally at 102, is provided with an internally threaded lower portion 104 which engages external threads 106 formed in the upper portion of flexible-walled container 108. It would be readily apparent to one skilled in the art that this securement between the chamber 102 and the container 108 may be accomplished by any other appropriate engagement method. Communication between the mouth 110 of the container 108 is provided by means of a flexible accordion tube 112 which extends into the measuring chamber 102. Preferably, tube 112 extends to about one-half the height of chamber 102 for dispensing its maximum dosage. Sealing between the measuring chamber 102 and the container 108 is accomplished by an annular shoulder 111 in the lower end of tube 112, which shoulder sealably abuts the top lip 115 of the container when the threaded engagement 104 is properly tightened.
Tube 112 is alternately elongated or compressed by means of an inverted U-shaped member 114 which connects the upper lip 116 to slide member 118. The upper lip 116 of the flexible accordion tube 112 is flanged so as to sealably engage the frustrum of an abbreviated, inverted cone-shaped plug 120 when the flexible tube is extended to its maximum length as shown in FIG. 12. This plug 120 is fixed in the inside upper portion of the variable dosage measuring chamber 102. Alternatively, sealing of the variable dosage measuring chamber 102 may be accomplished utilizing any other appropriate shapes or configurations wherein the upper end of the flexible accordion tube 112 is closed to the atmosphere.
In this embodiment of the present invention the appropriate dosage is selected by positioning slide member 118 at the appropriate position corresponding to the dosage to be administered. Advantageously, means are provided to maintain the slide member (and the flexible accordion tube attached thereto) at the desired position without moving. This can be accomplished by forming a plurality of vertically situated horizontal protrustions 122 along the periphery of the outside wall of the dosage measuring chamber adjacent the slide member 118. Slide member 118 is correspondingly provided with a horizontal notch 124 which frictionally engages protrustion 122 and maintains the flexible accordion tube 112 in the desired location. In the embodiment shown in FIGS. 10-12 there are provided three protrusions 122 spaced vertically along the side wall of the variable dosage measuring chamber 102 and are labelled from bottom to top respectively child, adult, and close (FIG. 10). By positioning slide member 118 at the "child" protrusion, the flexible accordion tube 112 is compressed to a predetermined length which would permit a children's dosage to be maintained within the measuring chamber 102 when the combined chamber-container assembly is inverted and restored to its original upright position.
Closure of this embodiment is accomplished by moving slide member 118 to its uppermost position (indicated by the protrusion adjacent the "close" position shown in FIG. 10) which causes the flanged lip 116 to sealably engage the frustrum of the inverted cone-shaped plug 120. In this manner, this embodiment of the apparatus may be sealed from contamination and spillage.
Dispensing of a measured dosage of fluid 126 is accomplished in substantially the same manner as described in the previous embodiments. Slide member 118 is positioned for the desired dosage and the chamber-container assembly is inverted to permit fluid contained in the reservoir to pass through the flexible accordion tube 112 and fill the chamber 102. The assembly is then restored to its upright position and any excess fluid above lip 116 of the tube 112 flows back into the reservoir 108 leaving a predetermined dosage within the chamber. Pressure is then applied to the flexible-walled container 108 to create a pressure differential between the inside of the chamber 102 and the ambient conditions thus forcing the measured dosage of fluid 126 contained within the chamber through discharge tube 130. This discharge tube is positioned within the chamber 102 with its lower end in close proximity to the lower portion 131 of the chamber. This lower portion is advantageously angled to facilitate complete dispensing of the fluid. The discharge opening (not shown) is outside the confines of the chamber and may exit out the top of the chamber (FIG. 10) or the side of the chamber (as shown in FIG. 6).
FIGS. 13-15 depict another preferred embodiment similar to that embodiment shown in FIGS. 10-12. A variable dosage measuring chamber 132 is threadably attached to a flexible-walled container 134. Engagement is accomplished by providing an internally threaded lower portion 136 which interlocks with the external threads 138 around the periphery of the mouth of the bottle 134. Communication between the reservoir of fluid in container 134 and the variable dosage measuring chamber 132 is provided by a telescoping tube member 140 made up of an inner tube 142 and an outer tube 146. The inner tube 142 is open on either end and fixed to the base portion 144 of the chamber 132. The outer tube 146 is slidably inserted over inner tube 142 in telescoping relationship. Preferably, outer tube 146 extends to about one-half the height of chamber 132 for dispensing its maximum dosage. The upper portion of outer tube 146 is flanged so as to sealably engage the frustrum of an inverted, abbreviated cone-shaped plug 148 fixed to the top portion 150 of the chamber 132 when the outer tube 146 is fully, vertically extended.
Sealing between the container 134 and the measuring chamber 132 is accomplished by means of a shoulder 152 formed in the lower end of the inner tube 142. As the internally threaded lower portion 136 of the chamber 132 is tightened onto the mouth of the container 134, the top edge of the mouth of the container 134 sealably abuts shoulder 152 creating a leak-proof passage between the container 134 and the chamber 132.
Outer tube 146 is vertically movable by means of an inverted U-shaped member 154 in which one arm 155 extends into the chamber 132 and attaches to the top edge 156 of the outer tube 146. A slide member 158 is attached to the other arm 157 of the inverted U-shaped member 154 and is movable between a plurality of vertical positions to vary the amount of fluid retained within the measuring chamber 132. In this embodiment of the present invention there are provided three positions between which slide 158 may be moved. These positions include a children's dosage (in phantom at 160 of FIG. 14), an adult dosage position shown in solid lines in FIG. 14 and a closed position shown in solid lines in FIG. 15. The slide position is maintained by means of horizontal protrusions 162 aligned vertically along the outer wall of the chamber 132. A horizontal notch 164 is formed in slide member 158 to frictionally engage protrusions 162 and maintain the slide in the desired position.
The measured fluid is expelled from the chamber through a discharge tube 166 which extends from the base portion 144 of the discharge chamber 132 vertically through the upper portion of the chamber for delivery of the measured fluid to the desired location. The bottom edge of tube 166 is preferably angled as shown in FIGS. 14-15 to facilitate accurate and complete discharge of the measured fluid.
FIGS. 16 and 17 show an embodiment of the present invention wherein chambers 180 and 182 interconnect with separate reservoirs 184 and 186, respectively, in the same dispenser. In this embodiment chamber 180 and reservoir 184 are separate and independent from chamber 182 and reservoir 186 thus allowing the simultaneous measuring and dispensing of two separate fluids in a single operation. This ability is particularly useful where two reactive fluids are to be mixed prior to use.
Chambers 180 and 182 can be designed to measure either equal or different amounts of fluid. In the embodiment of FIGS. 16 and 17, inlet tubes 188 and 190 extend varying lengths into chambers 182 and 180, respectively, to measure and retain different amounts of fluid 192 and 194 when the dispenser is inverted and righted.
Dispensing is accomplished in the same manner as described in the previous embodiments. Where two reactive fluids are to be mixed outside the chambers, the conduit and venting means 198 and 196 can be brought together in a mixing chamber 200 just prior to expulsion from the conduit and venting means.
Other embodiments are also possible for retaining varying amounts of separate fluids. These include varying the overall capacity of either chamber or by incorporating a moveable partition between the measuring chambers to measure out preselected amounts.
Although particular illustrative embodiments of the present invention have been described herein, the present invention is not limited to these embodiments. Various changes, substitutions and modifications may be made thereto by those skilled in the art without departing from the spirit or scope of the invention defined by the appended claims.
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A device is provided for controlled dispensing of a measured quantity of fluid from a flexible wall container. The device has a chamber adapted to hold a measured quantity of fluid when the container is inverted and righted. This fluid is then dispensed from the chamber through a conduit in direct response to a force exerted on the flexible wall of the container.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation of U.S. application Ser. No. 08/006,381 filed Jan. 19, 1993, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is concerned with a device for applying and dosing liquid or pasty substances onto moving surfaces, such as paper or cardboard webs, for example. Preferably, the inventive device takes the form of an application or dosage roll.
2. Background Technology
The amount of pasty substance applied to a moving web from an application or dosing roll can generally be controlled by the following measures:
a) by changing the gap between two cooperating rolls;
b) by having a difference between the velocities of two cooperating rolls; and/or
c) with the aid of a blade pressed on the roll with variable force.
Volumetric control of the amount of substance applied is not possible. This means that, by having an appropriate gap width, for example, between two cooperating rolls, the amount applied is controlled by the cross-section of the particular gap section.
Other application methods involve rolls with small surface cups from which excess substance is scraped off to a predetermined height, as well as a pair of rolls, of which one has a desired surface profile. In this case, the gap between the rolls can be adjusted. However, in order to obtain variable volumetric control of the amount applied, it is necessary to change rolls which, of course, involves interruption of production.
SUMMARY OF THE INVENTION
It is an object of the invention to overcome one or more of the problems described above.
According to the invention, control of a variable amount of a substance applied from an applicator roll onto a web guided under tension over a dosage roll is provided. The invention is directed to an application device in which an applicator roll cooperates with a counter roll, with the formation of an application gap, in order to make a desired amount of coating material available for another applicator roll or for direct application from the counter roll onto a paper or cardboard web guided over it.
Further 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
The invention will be explained below with the aid of the embodiments shown in the drawing. The following are shown:
FIGS. 1a and 1b are axial sections through first and second embodiments of a roll of the invention, illustrating the principle of operation thereof;
FIG. 2 is a perspective view of a third embodiment of a roll of the invention;
FIGS. 3 and 4 are an axial cross-section and a partial front view, respectively, of a fourth embodiment of the roll of the invention; and
FIGS. 5 to 7 are schematic representations illustrating specific applications of the roll of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The application and dosage device of the invention comprises a roll, optionally with an external shell, having a diameter which can be varied by the application of energy and which, under predetermined controllable conditions, has a variable thickness along the length of the roll (or external shell) as a function of space and/or time.
Fundamentally, according to the invention, the amount of a substance available can be adapted to the requirements of the particular operation; this can depend on the type of material applied (i.e., the coating material), on the rate of application (i.e., the velocity of the paper or cardboard web), on the amount needed to be applied, on the absorbency of the substrate (paper or cardboard, for example), etc.
FIG. 1a illustrates a rotatable and readily deformable roll shell 1, preferably formed of rubber or a similar highly elastic synthetic material, inside of which is disposed a substantially cylindrical support 3, formed of steel, for example, and which preferably also rotates, either in the same direction as the roll shell 1 or in the opposite direction. The space between the support 3 and the roll shell 1 is subdivided into individual chambers 5 by a plurality of ring lands 2. An excess pressure or, preferably, reduced pressure can be applied to the chambers 5 with the aid of a working fluid (for example, a hydraulic fluid or preferably a gas, such as air). For this purpose, the ring lands 2 each have one or, preferably, several throughbores 12. The roll shell 1 is deformed in the region between the ring lands 2 upon the application of reduced or excess pressure, such that the roll shell 1 will assume a wavy surface, as indicated in FIG. 3 by the dotted line curve 30. Naturally, the roll shell 1 must remain tightly fixed against the ring lands 2 during operation, so the roll shell 1 is preferably shrink-fitted onto the lands 2.
The degree of waviness (i.e., the amplitude and wavelength) of the shell 1 can be increased or decreased by the magnitude of reduced or excess pressure, with a wavelength preferably between 0.3 and 1 mm. Of course, the spacing between the ring lands 2 must be correspondingly small.
A similar embodiment is shown in FIG. 1b, in which the introduction of the working fluid is done through a hollow cylindrical support 3' with radial throughbores 17. Spacer rings 16 are provided for individual ring lands 2' in order to form individual pressure chambers 5'. Working fluid is introduced through a central pressure chamber 18 with a hollow cylindrical support 3'. The individual ring lands 2' are tensioned against one another in practice with the aid of the spacers 16, and their spacing is thus accurately established. Naturally, the ring lands 2' must also have throughbores which must be at least partially contiguous with the throughbores 17 of the cylindrical support 3'. In this case, it is possible to produce axially varying local pressures in sections by pressure chambers assigned to the various axial sections of the support 3', and thus locally variable waviness can be produced in the roll shell 1.
FIG. 3 shows a variation of a roll 1' in which individual annular pressure stamps 25 are provided in opposed axial spacing with relation to a hollow cylindrical support 23. The pressure stamps each comprise individual ring segments 25, 25', 25", etc., as shown in FIG. 4. Ring wheels 26, onto which a deformable roll shell 21 is pressed, are disposed between the pressure stamps 25. By introducing a working medium through radial bores 22 in the support 23 to the inside of the stamps (rings) 25, at these points the diameter of the roll shell 21 will increase so that the wariness shown by the dotted line 30 will be achieved.
In FIG. 2, individual surface elements 13 protrude from and are guided by the radial outside surface of a roll shell 9. The elements 13 comprise piezoelements, the lengths of which are variable whereby their radial outer, free end surfaces define a wrapper cylinder which has a variable diameter. The piezoelements 13 are disposed in individual cylinder segments 14 which have assorted electrical wires 36 loading to a source of electricity.
Naturally, the radially outer (front) surfaces of the stamp lie on an (imaginary) wrapper cylinder which can also comprise a flexible shell of, for example, rubber.
This variability of the surface of the roll 6 depends on the inverse piezoelectric effect, so that upon application of an electrical field parallel to the direction of polarization of the piezoelectric crystal of the elements 13, expansion of the element 13 in the same direction is obtained. The component with the piezoelectric (inverse) effect is also called a piezoelectric translator (or briefly, piezotranslator).
Naturally, by the application of external magnetic electrical fields, the length of small stamps made of the appropriate materials can be influenced.
Thus, a roll with an irregular surface is obtained, whereby depressions exist between the individual stamps and the coating material which is introduced into these depressions.
The situation is similar to that of the wavy surface of the roll shell 1 or 21 of FIGS. 1 and 3, respectively, in which the coating material is taken up in the valleys of the waves. This form of ductor or dosage element is known in the art as wire-wound cylindrical rods or rolls. Such dosage rods are also obtained by incorporation of grooves into a rod or cylinder. In the case of the devices known in the art, these grooves are very fine and have a cross-section between 0.001 and 0.40 mm 2 . Correspondingly structured heat fields or electromagnetic radiation can also produce a corresponding waviness on a mantle surface when the material is chosen appropriately.
FIGS. 5 to 7 show individual coating devices, in which paper webs W are coated with pasty or liquid compositions. A transfer gap between a roll 1 (alternatively 1' or 6) of the invention and a counter roll 31, 41 or 51, is always formed. In FIG. 5, the respective directions of rotation of the two rolls 1 (1', 6) and 31 can be the same or opposed. In FIG. 6 the directions of rotation of the rolls 1 (1', 6) and 41 can be opposed. In FIG. 7 the rotation directions of the rolls 1 (1', 6) and 51 are the same.
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 device for applying and dosing liquid or pasty materials onto moving surfaces, especially onto paper or cardboard webs, is provided. The invention is characterized by a roll, optionally with an outer shell, the diameter of which can be controlled by the application of energy and, under predetermined or desired controllable conditions provides local variations in diameter along the length of the roll or roll shell as a function of time and/or space.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 12/939,158, entitled CHUCK FOR HOLDING PRECISION COMPONENTS filed on Nov. 3, 2010, which claims priority from U.S. Provisional Application No. 61/257,615, filed Nov. 3, 2009, the entire disclosures of which are hereby expressly incorporated herein by reference.
TECHNICAL FIELD
This invention relates to a chuck for holding components, and specifically to a chuck used to hold components in a machine for precision working of components.
BACKGROUND
Chucks are mechanisms removably hold and/or secure a part or tool. Some chucks operate by manipulation by the operator to clamp onto and secure and/or unsecure a part or tool. For example, a conventional three jaw chuck requires the operator to loosen the jaws to insert the item to be held and to tighten the jaws to clamp down on and secure the item. Other bit holders may automatically clamp onto and secure an item when the user inserts the item into the chuck, or require an action by the operator, such as twisting the chuck body by hand or using an external device, such as a key or other tool, to secure and/or unsecure an object to be held.
SUMMARY
According to a first embodiment, a chuck assembly is provided comprising a mandrel portion including an extending member sized and shaped to hold a workpiece; and a piston including a bore receiving the extending member, the piston mounted for supported movement on and relative to the extending member, the piston moving between a first position and a second position, the first position providing for insertion and removal of the workpiece to and from the extending member, the second position causing gripping force to be applied to the workpiece in at least two locations that are spaced longitudinally along the workpiece to inhibit relative movement between the mandrel and the workpiece.
According to another embodiment, an assembly for holding a workpiece is provided comprising a mandrel portion including an extending member; a piston including a bore receiving the extending member, the piston mounted for supported reciprocal movement on the extending member, the piston including plurality of tabs having internal and external surfaces, the tabs being able to deflect to bring the internal surfaces into engagement with the extending member; and a set of jaws mounted for pivotal movement, each jaw of the set of jaws including a surface positioned to receive force exerted by the external surfaces of the piston, wherein movement of said piston exerts force via the external surfaces of the piston and causes pivotal movement of said set of jaws.
According to yet another embodiment, an assembly for holding a workpiece is provided comprising a mandrel portion including an extending member; a piston including a plurality of tabs cooperating to define a bore receiving the extending member, the piston mounted for supported reciprocal movement on and relative to the extending member; a set of jaws mounted for pivotal movement, wherein movement of said piston causes pivotal movement of said set of jaws, wherein each jaw of the set of jaws includes a clamping surface operable to frictionally engage a workpiece placed within the chuck assembly, pivotal movement of said set of jaws altering an angle assumed by the clamping surface.
Other features, elements, characteristics and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the present invention with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of the chuck assembly according to an exemplary embodiment.
FIG. 2 is a perspective view of the chuck assembly.
FIG. 3 is a cross-sectional view of the along the longitudinal axis of the chuck assembly.
FIG. 4 is an enlarged cross-sectional view of a chuck housing end of the assembly shown in FIG. 3 .
FIG. 5 is a cross-sectional view of a chuck assembly similar to FIG. 3 .
FIG. 6A is a cross section side view of a mandrel of a chuck assembly according to an exemplary embodiment.
FIG. 6B is a rear view of the mandrel shown in FIG. 6A .
FIG. 6C is a side view of the mandrel shown in FIG. 6A .
FIG. 6D is an enlarged view of the circled area of FIG. 6A .
FIGS. 7A to 7D shows various views of a piston of a chuck assembly according to an exemplary embodiment.
FIG. 8A is a perspective view of a jaw of a chuck assembly according to an exemplary embodiment.
FIG. 8B is a top view of the jaw shown in FIG. 8A .
FIG. 8C is a cross section view of the jaw shown in FIG. 8A .
FIGS. 8D and 8F are side views of the jaw shown in FIG. 8A .
FIG. 8E is a rear view of the jaw shown in FIG. 8A .
FIGS. 9A to 9F show various views of a housing of a chuck assembly according to an exemplary embodiment.
FIGS. 10A and 10B show a cross section view of a second embodiment chuck assembly employing the piston of FIGS. 7A-D .
FIG. 11A and 11B another cross section view of the second embodiment chuck assembly of FIGS. 10A and 10B .
DETAILED DESCRIPTION
Finish grinding of some injection system components, i.e. injector plungers or needles, requires special work holding and clamping methods to achieve required roundness and end-to-end run out specifications. Some injector needles are quite long, e.g. greater than 130 mm, and small in diameter, e.g. diametral cross section of 4 mm. Needles often include other portions or diametral sections along its length having larger diameters, such as 6 mm and 8 mm. This needle configuration requires a chuck that can receive these extra long parts and have enough chuck jaw travel to accommodate the diametral differences of the different needle sections, and yet be accurate and repeatable to less than 0.005 mm when clamping work pieces.
There do not appear to be any standard off-the-shelf clamping devices that perform this work holding function sufficiently to satisfy the above-mentioned requirements.
The chuck of the present invention is specifically dedicated to provide proper work holding during needle grinding operations to achieve required roundness and run out specifications. The chuck of the present invention is designed to enable grinding of either end of the needle, also referred to as the needle valve element or plunger. The part to be machined can be simply turned around endwise if necessary. Conventional grinding operations require two distinct operations with different chucks for each end of the needle. The chuck change over between the two grinding operations was minimized and without any additional work holding.
Major features of the chuck of the present invention include enabling greater precision machining with accuracy and repeatability (run-outs) of less than 0.005 mm. In addition, the chuck accepts parts (needles) with large length to diameter (L/D) ratios, can hold parts up to 150 mm in length, and has a jaw that opens through a wide range, for example, 6 mm, i.e. a jaw opening of 3 to 9 mm, or 4 to 10 mm, etc. Conventional chucking devices of similar accuracy have an opening range of 0.2 mm.
The chuck of the present invention effectively holds small works, such as needle valve elements or plungers used in fuel injectors, thereby improving the extent, accuracy and precision of grinding throughout grinding operations.
Referring now to FIGS. 1-6 , an embodiment of a the chuck includes a mandrel 1 . As shown, the mandrel has a #5 Morse taper to fit a standard work head of the grinding machine, although the taper can alternatively be another size, such as a #4 taper, or a flange mounting may be used. Mandrel 1 also serves as a base mounting for all other chuck components.
The chuck also includes a chuck housing 3 , a piston 2 positioned for sliding guided movement on an extension 4 formed on mandrel 1 , and three jaws 5 positioned in, and mounted on, housing 3 . Housing 3 functions as the main chuck body, mounts to the mandrel 1 , and houses jaws 5 . Piston 2 is preferably air actuated but can be actuated by pressurized oil. Piston 2 moves axially along the chuck and mandrel extension 4 between extended and retracted positions to provide motion for, or cause movement of, the chuck jaws 5 . Movement of piston 2 in a forward axial direction toward the extended position away from mandrel 1 causes jaws 5 to close or move toward a closed position. Movement of piston 2 in a reverse axial direction away from mandrel 1 causes jaws 5 to open or move toward an open position. One or more piston return springs 6 , positioned between the housing and a piston flange, biases the piston 2 toward the retracted position away from housing 3 thereby moving the piston 2 in a reverse direction when the air or oil pressure is shut off.
Jaws 5 are each pivotally mounted on a jaw retaining assembly 8 (bushings, spacers and/or pins), as shown in FIG. 1 , to pivot in a radial plane extending radially from the centerline axis of the housing 3 . Each jaw 5 pivots around a pivot axis 11 extending perpendicular to the radial plane so that a clamping end of each jaw 5 moves in a clamping direction toward the centerline axis of the housing 3 when piston 2 moves toward its extended position.
Referring now to the FIGS. 8A to 8F , which show more detailed views of an exemplary jaw 5 , and FIGS. 9A to 9F , which show detailed views of an exemplary housing 3 , the housing 3 includes three jaw slots 12 formed within the housing and spaced equally around the circumference of the interior of housing 3 . Each jaw slot 12 is sized to receive and guide one of the jaws 5 during pivoting movement. Each jaw retaining assembly 8 (see also, FIG. 1 ) extends through the housing 3 , a passage 14 formed in the respective jaw, and back into the housing 3 to pivotally mount and retain the jaw within the slot. Thus, jaws 5 can be mounted using precisely fitted bushings 18 a , 18 b to ensure stability and repeatability. Each jaw 5 also includes a driven end 13 having a curved inner surface for driven abutment or contact by a tapered portion 16 of a driving end of piston 2 (see, FIG. 4 ). Preferably the tapered portion is cone, or frusto-conically, shaped, for example, as shown in FIGS. 7A to 7D . Tapered portion 16 includes a plurality of tabs 30 that are formed via a plurality of gaps 32 formed in tapered portion 16 . Piston 2 also includes a plurality of gaps 34 defined in cylindrical portion 36 . Gaps 32 , 34 allow tabs 30 to deflect or flex when force is applied that urges tabs 30 radially inward.
A jaw return spring 10 is mounted at the driven end in a retaining opening 24 of each jaw to bias the driven end of the jaw toward and into abutment with the driving end of piston 2 , and thus biasing jaw 5 toward a refracted position around pivot axis 11 .
A part stop 24 is replaceably positioned within a conical bore formed in the mandrel extension to provide a fixed stop against which the workpiece or part, i.e. injector needle element, is positioned when inserting the part into the chuck. A plurality of interchangeable part stops having different length can be provided.
A replaceable jaw insert 9 may be provided on the clamping end of each jaw 5 to accommodate different clamping diameters. Jaw inserts can be attached to the top portion of each jaw 5 using screws 27 a , 27 b in openings 28 a , 28 b (see, FIGS. 4 and 8B ) and are designed for quick change over (and replacement) to accommodate different work pieces. A jaw insert adjuster 7 , mounted adjacent each insert 9 at 30 (see, FIG. 8E ), permits the position of each insert 9 to be adjusted radially to achieve required run outs. This is accomplished by the jaw inserter adjuster 7 .
Piston 2 is matched to the mandrel extension or arbor with a minimal clearance to permit smooth sliding yet well supported reciprocal movement. Piston 2 is also designed to collapse onto the mandrel in full closed position to provide stability and repeatability. Controlled air leakage thru the piston/mandrel clearance can be provided to reduce or prevent debris from entering cylinder chamber and ensure free sliding motion.
Jaw insert adjuster 7 is a micro adjusting screw to enable zeroing of the radial run out of the work piece to a desired accuracy. A set up detail (spider, not shown) is also designed to fit jaws for jaw grinding under a clamped condition if so desired. The spider is a ring with dowel pins that can be inserted into inner mounting holes of the jaw inserts so the jaws can be closed (clamped) for grinding of jaw inserts. Precisely adjusted jaws 5 will provide radial run out accuracy of 0.005 mm (or better) while maintaining a large range of opening clearance/motion (8 mm diametral) to accommodate different part geometries.
In use, the work piece or part 20 is inserted into the chuck against part stop 24 . A part guide 15 may be used as a loading aid to help guide the part 20 into the chuck when manually clamping/loading. Air or pressurized oil is supplied to the piston area through a rotary coupling, air tube/passageway, and internal drillings. For example, FIGS. 3-6 show an air passageway 17 , which splits into plural passageways before entering the area of the housing 3 near the piston 2 . Upon supplying air pressure, piston 2 moves forward causing the jaws 5 to pivot and clamp the part. Forward movement of piston 2 that engages jaws 5 , further places a radially-inward-directed force on tabs 30 . Such force causes tabs 30 to deflect radially inward to squeeze extension 4 which, in turn grips the workpiece 20 at a proximal end. Accordingly, it will be appreciated that engagement of piston 2 with jaws 5 (which further clamp workpiece 20 ) creates a closed force loop (illustrated at 100 ). The force loop provides that workpiece 20 is gripped at two locations (by the jaws 5 and by tabs 30 ). The force loop further provides that the grip at one grip location cannot be loosened without imparting greater grip force at the second grip location. An illustration of such a force loop is provided in FIGS. 10A and 10B , which is directed at a second embodiment mandrel 1 ′ that uses the same jaws 5 and piston 20 .
For parts that are required to protrude from the chuck, an auxiliary center support 22 can be used. To unclamp the work part, air supply to the chuck is shut off. With the air shut off, piston return springs 6 return piston 2 to its home position, and jaw return springs 10 pivot the jaws back into their home position.
A chuck mounted dressing disk may be used for wheel dressing. During chuck set-up, jaw inserts 9 are adjusted for required concentricity using jaw insert adjusting screws 7 and appropriate dial (or digital) indicator. This chuck can be used for precision grinding, turning, or whenever precise clamping of long and slender parts is required.
As previously noted, FIGS. 10A and 10B , shows a second embodiment mandrel 1 ′ that uses the same jaws 5 and piston 2 . Mandrel 1 ′ installs into a grinding machine work head via a Morese Taper. Mandrel 1 ′ includes holes in a flange and is bolted to a face of a machine work head spindle. It should be appreciated that FIG. 10A is not a pure cross-section, but rather as shown on FIG. 10B , is a cross section that changes section at the mid-line of mandrel 1 ′( 10 A- 10 A). This change in section is provided such that multiple jaws 5 are shown. Of course, there are actually three jaws 5 and all jaws 5 participate in the force loop. Again, the force loop provides that workpiece 20 is gripped at two locations (by the jaws 5 and by tabs 30 ). The force loop further provides that the grip at one grip location cannot be loosened without imparting greater grip force at the second grip location. Still further, when engaged, tabs 30 include inner and outer surfaces that are both applying forces that cause gripping of work piece 20 . Inner surfaces of tabs 30 apply force to extension 4 which translates to grip work piece 20 . Outer surfaces of tabs 30 apply force to jaws 5 which are urged to pivot about pivot axis 11 such that jaw insert 9 is urged into and exerts force on workpiece 20 .
Mandrel 1 ′ differs from mandrel 1 in the nature of the disengagement of piston 2 and the release of workpiece 20 . As shown in FIGS. 10A and B, springs 40 are included that bias piston 2 to an engaged position. Springs 40 are crafted to provide enough force on piston 2 to cause piston 2 to remain in the engaged position absent pneumatic or hydraulic pressure acting thereon. Accordingly, in one embodiment, springs 40 are matched with springs 6 and/or 10 such that regardless of the position of piston 2 , piston 2 is held in such position absent the application of additional force.
FIGS. 11A and 11B show hydraulic/pneumatic pathways 44 , 46 and pistons 42 that provide additional force to move piston 2 between engaged and disengaged positions. Like FIGS. 10A and 10B , FIG. 11A is a cross-section that changes section at its midpoint ( 11 A- 11 A). This change in section allows for multiple fluid pathways to be illustrated. Pathway 44 operates similarly to previously discussed passageway 17 such that fluid supplied thereto causes engagement movement of piston 2 . Pathway 46 leads to pistons 42 . In the present embodiment, there are three pistons 42 positioned to selectively engage piston 2 . When pressurized fluid is supplied to pathways 46 and to pistons 42 , pistons 42 extend to urge piston 2 to a disengaged position.
While an exemplary embodiment in accordance with the claimed invention has been shown and described, it is understood that the invention is not limited thereto. The present invention may be changed, modified and further applied by those skilled in the art. Therefore, this invention is not limited to the detail shown and described previously, but also includes all such changes and modifications within the scope of the following claims and their equivalents.
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A chuck assembly comprising a mandrel portion including an extending member sized and shaped to hold a workpiece; and a piston including a bore receiving the extending member, the piston mounted for supported movement on and relative to the extending member, the piston moving between a first position and a second position, the first position providing for insertion and removal of the workpiece to and from the extending member, the second position causing gripping force to be applied to the workpiece in at least two locations that are spaced longitudinally along the workpiece to inhibit relative movement between the mandrel and the workpiece.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a drive mechanism for an automatic washer and more particularly to a device to allow for a delay between the start of rotation of a driving member and the start of rotation of the driven member in an automatic washer agitator drive.
2. Description of the Prior Art
In the drive of an automatic washer, the agitator is driven either in a back and forth agitate motion or in a single direction spin motion depending on the particular portion of the wash cycle. Various clutching mechanisms have been provided in the prior art to provide a transition between oscillatory agitation motion and rotating spin motion.
U.S. Pat. No. 2,609,697 discloses a drive dog 42 depending downwardly from the agitator skirt which engages a drive dog 43 on the basket to carry the agitator and basket together during a spin mode and during the agitate mode it is stated that the downwardly depending dog 42 will push the basket dog 43 out of the way during the first oscillation and then will not contact it during subsequent oscillation.
U.S. Pat. No. 3,248,908 uses an inner and outer helical spring type clutch 30 to permit oscillatory motion of the agitator without causing oscillation of the basket, but continued rotation in one direction during spin will cause the clutch 32 engage thus spinning the basket with the agitator.
U.S. Pat. No. 4,059,975 uses a pivoting arm 180 to alternatively be engaged by opposed cam surfaces on adjacent pulleys which are rotated in opposite directions to result in oscillatory motion when the pulleys are rotated in a first direction and results in a spinning of the agitator when the pulleys are rotated in a second direction.
It is desirable in washers to provide a means for driving the basket and agitator in a spin mode and only the agitator in an agitate mode. All the prior art has provided some solutions for providing this function, these solutions are somewhat complicated and use involved clutching mechanisms and connecting parts.
Therefore, it would be an improvement in the art if there were provided a simple, yet effective means for permitting oscillatory motion of the agitator without causing oscillatory motion of the basket, and for causing spinning of the basket upon a given rotation of the agitator, without the need for a complicated and expensive clutch arrangement.
SUMMARY OF THE INVENTION
The present invention provides a rotational delay mechanism for a single shaft agitate and spin drive for automatic washers which permits the use of a single shaft to drive both the agitator and spin basket in a spin mode, but which permits oscillation of the agitator without rotational movement of the basket in a wash mode. Further, the present invention provides for a simplified clutch arrangement which is a rotational delay mechanism with means for easily varying the length of delay so that it can be assured that the agitator is free to oscillate through any given oscillatory stroke angle, even one of several rotations, without causing the spin basket to be driven, yet assuring that the spin basket will be driven in a spin direction after the agitator has been rotated beyond the preselected stroke angle.
The delay mechanism is comprised of a plurality of disc members to be stacked on the agitator shaft, each disc having opposed axially extending tab or lug portions such that the extending portion of one disc will abut against an extending portion of a neighboring disc after sufficient relative rotation of the two discs. A driver such as a pulley rotated by a motor drives a lowermost disc and an uppermost disc drives a spin tube attached to the basket. Thus, when stacked on the agitator shaft, each disc will be rotated a given number of degrees before its projection engages the projection on the next adjoining disc. During agitate, the driver rotates in its oscillating motion fewer degrees in one direction than is required for the combination of all the discs to rotate sufficiently to provide a driving input to the spin tube. The number of turns the disc adjacent the driver makes before the disc at the other end adjacent the spin tube begins to rotate is the angular delay and is determined by the number of discs and the size of the discs. When the driver rotates in a single direction, the lost motion device eventually locks up, providing a continuous rotational input to the spin tube.
Two different embodiments of the disc are disclosed as exemplary embodiments of the invention. In a first embodiment, the discs comprise a generally circular member with a central hole for passage of the agitator shaft and have two radially extending tabs, one tab being turned upwardly in an angled axial direction and the opposite tab being turned downwardly in an angled axial direction. Thus, when the discs are stacked on the agitator shaft, an upwardly turned tab will engage with a downwardly turned tab of the next adjacent disc to provide the driving connection between the discs. In this manner, each disc may provide at least approximately 340° of lost motion. If the disc is made of a larger diameter, and the tab remaining approximately the same size, then the effective angular width of the tab would be reduced such that a larger number of degrees of lost motion could be obtained from each disc.
A second embodiment illustrated in this disclosure comprises a disc with a planar lower surface broken only by a downwardly extending tab or lug axial projection molded as part of the disc close to the outer perimeter of the disc. The top side of the disc includes an upwardly extending rim extending around the entire periphery of the disc and an upwardly extending tab or lug projection, radially opposite the downwardly extending projection, which terminates coplanar with the perimeter wall. A central hub portion is also formed which extends upwardly from the disc so that an annular channel is formed in the top side throughout approximately 340° of the circumference of the disc, the remaining 20° being filled with the upward projection. When two such discs are stacked, the lower projection of the upper disc fits down into the annular channel of the lower disc and the discs are free to rotate relative to one another until the adjacent upward and downward projections abut. Then the two discs are carried together in a given rotational direction. In this embodiment there is also preferably provided an elastomeric bumper which is held in the topside of the disc and which projects to either side of the upwardly directed projection so that the bumper is engaged by the downwardly directed projection before that projection engages the upwardly extending projection thereby to act as a cushion and to avoid the impact of one projection against the other thereby to reduce or eliminate any noise associated with such impact.
As with the first embodiment, the amount of lost motion can be changed by changing disc size or number of discs. Thus, there is provided a simple, yet effective means for permitting oscillatory motion of the agitator without causing oscillatory motion of the basket, and for causing spinning of the basket upon a given rotation of the agitator, without the need for a complicated and expensive clutch arrangement.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a washing machine, partially cut away, embodying the principles of the present invention.
FIG. 2 is a side sectional view through the interior of the washing machine of FIG. 1.
FIG. 3 is a side elevational view of the agitator shaft showing a first embodiment of the discs of the present invention.
FIG. 4 is a sectional view taken generally along the line IV--IV of FIG. 3.
FIG. 5 is a sectional view of the agitator shaft and disc taken generally along the lines V--V of FIG. 3.
FIG. 6 is a side sectional view illustrating a second embodiment of the discs incorporating the principles of the present invention.
FIG. 7 is a top sectional view of the agitator shaft and discs taken generally along the line VII--VII of FIG. 6.
FIG. 8 is a perspective view of a disc illustrated in FIGS. 6 and 7.
FIG. 9 is a top view of a plurality of stacked discs.
FIG. 10 is a side elevational view of a plurality of stacked discs.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 there is illustrated an automatic washer generally at 10 having an outer cabinet 12 to surround and enclose a wash load receptacle and drive mechanism. The wash load receptacle is composed of an imperforate wash tub 14 and a concentric inner perforate wash basket 16. A vertical axis agitator 18 is concentrically located within the wash basket 16 and is driven by means of an agitator shaft 20 which extends through the floor of the wash basket 16 and wash tub 14 to be driven by an electric motor 22 through an appropriate power transmission arrangement such as that described below. The washer cabinet 12 has a top openable lid 24 and has a console 26 at the rear edge of the top of the washer which includes a plurality of control dials 28 to permit a user to select a series of automatic washing, rinsing and dehydration steps.
The interior of the washer is shown in greater detail in FIG. 2 where it is seen that the agitator 18 is connected to the agitator shaft 20 by appropriate fastening means which may include a spline connection 30 and a retaining screw 32. The agitator shaft extends downwardly and is secured to a driven pulley 34 which is connected by means of a drive belt 36 to a drive pulley 38 mounted on a drive shaft 40 of the motor 22. Thus, the agitator is driven by the motor 22 through the pulley and drive belt transmission arrangement. This type of a drive arrangement has many advantages, such as being able to quickly change pulley diameters to cause the machine to run at different speeds, for example when switching between 60 cycle current and 50 cycle current in different countries.
The wash tub 14 and wash basket 16 are shown as being suspended from the suspension rods 42 which are resiliently mounted to a base plate 44 beneath the wash basket and wash tub. The motor and drive connection are all suspended from the base plate 44.
During a normal wash cycle, the agitator 18 is oscillated about its vertical axis such that lower vanes 46 operate as pumping arms to cause a toroidal flow of wash liquid downwardly along the agitator body, outwardly along the skirt 48 of the agitator and upwardly along the wall of the wash basket 16. This toroidal flow increases turnover of the clothes in the wash basket thus enhancing washability.
During the dehydration or liquid extraction stage of the wash cycle, the wash basket 16 is spun at high rate of speed to cause a centrifugal extraction of the wash liquid through the perforate wall of the basket. The wash basket 16 is driven by the motor 22 through the connection of a spin tube 50 which connects to the wash basket at a top end and which is indirectly connected to the driven pulley 34 at a bottom end by means of a delay mechanism shown generally at 52. A first embodiment of the delay mechanism is shown in greater detail in FIGS. 3-5 which illustrate a plurality of stacked discs 54 carried on the agitator shaft 20. Each individual disc comprises a generally circular member having an upstanding circumferential wall 56 extending axially from a floor portion 58. A central hub portion 60 also projects axially upwardly and terminates at a top wall 62 which is coplanar with a top wall 64 of the circumferential wall. Thus, an annular channel 66 is formed between the circumferential wall 56 and the hub 60. An axially upwardly extending lug or tab 68 is positioned in the annular channel 66 which also terminates flush with the tops of the circumferential wall and hub. In the top disc, there is mounted a connecting element 70 which provides the driving connection between the top disc and the spin tube 50. In each of the remaining discs there is mounted an elastomeric bumper 72 in a space between the hub 60 and the upwardly projecting lug or tab 68. The elastomeric bumper 72 projects beyond the side walls of the lug 68 into the annular channel.
On the bottom side of each disc there is a downwardly projecting tab or lug 74 which is spaced slightly inwardly from the circumferential edge of the disc so that when two discs are stacked together, the downwardly projecting lug of an upper disc will be received in the annular channel of the lower disc. The lowermost disc has its downwardly projecting tab 74 extending into an annular channel between the pulley rim and the pulley hub where it is engagable by an upwardly axially extending drive lug 76 formed on the pulley. Thus, as the pulley rotates, the drive lug 76 will engage the downwardly depending lug on the bottom disc causing the bottom disc to rotate with the pulley. Upon continued rotation of the pulley and drive disc in the same direction of rotation, the bottom disc will rotate until the upwardly extending lug 68 of the bottom disc approaches engagement with the downwardly extending lug of the next upwardly adjacent disc.
Just prior to engagement of the two opposed lugs, the elastomeric bumper 72 carried by the bottom disc will engage the downwardly depending lug 74 of the next upper disc. This is illustrated in FIG. 4 wherein the downwardly extending lug 74 of the next upper disc is shown in full at the 2 o'clock position and is shown in dotted lines in engagement with the bumper at the 10 o'clock position. By providing the resilient bumper, the driving engagement between adjacent discs is cushioned at the point of impact to reduce or eliminate noise and to reduce shock to the parts. Once the bottom two discs are engaged together by the opposing lugs, they both rotate with the pulley and in succeeding fashion each of the remaining upper discs are picked up and carried in rotation until finally the top disc is picked up which causes the spin tube to rotate.
As can be seen in FIGS. 4 or 5, each lug comprises an angular extent of approximately 20°, thus providing loss motion of approximately 340° per disc. This amount of lost motion can be reduced by making the disc smaller while keeping the lug approximately the same size, therefore the lug comprising a larger relative angular extent, and the amount of lost motion per disc can be increased by reducing the size of the lug or making the disc larger so that the lug will comprise a relatively smaller angular extent. The total lost motion of the system can be changed by changing the number of discs which are in the stacked arrangement, each new disc adding the per disc angle of lost motion. Thus it is seen that several rotations of lost motion are easily obtainable through the use of a few discs.
Therefore, during the agitate portion of the motion, the motor may be operated in an oscillatory manner to provide alternating rotation to the agitator shaft 20. Since this alternating motion would be held below the amount of lost motion attributable to the disc stack, the wash basket would not be driven during this phase of the wash cycle. However, when the wash cycle moves into the spin phase, the motor would be operated in a single direction and, after sufficient number of rotations of the pulley 34, all of the discs would be picked up and the basket 16 would be rotated along with the agitator 18 to provide the centrifugal extraction of the wash liquid from the clothes load.
An alternative embodiment of the lost motion device is illustrated in FIGS. 6-10 in which a plurality of discs 80 (seen best in FIG. 8) are stacked on the agitator shaft 20 to provide the desired lost motion. Each disc 80 is comprised of a circular member having a first radial tab or lug 82 which is bent or angled axially upwardly and a second, opposed tab or lug 84 which is bent or angled axially downwardly. The lowermost disc 80 has its downwardly extending lug 84 captured in a cut out 86 in the driven pulley so that it will rotate with the pulley. As the lower discs are successively picked up during rotation of the pulley, the top ring is finally also picked up so that the entire stack of discs will rotate. A connecting member 88 connects the top disc to the spin tube 50 to provide rotation of the spin tube once all of the discs have been picked up.
As in the first described embodiment of FIGS. 3-5, the angle of lost motion per disc with the second embodiment can be changed by changing either the size of the lugs or the diameter of the discs and the overall lost motion can be changed by increasing or decreasing the number of discs in the stack.
Thus, with both embodiments, there is provided a lost motion mechanism which permits a single drive arrangement, that being of the pulley 34 and the associated agitator shaft 20 to impart oscillatory motion the agitator 18 without effecting movement of the wash basket, even if the oscillation of the agitator extends through more than a 360° agitation stroke. Once the driven pulley 34 is rotated beyond the lost motion angle, then the wash basket 16 is automatically picked up and rotated along with the agitator without the need for additional or special clutching arrangements other than the very simple stacked disc arrangement.
As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceeding specification and description. It should be understood that I wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of my contribution to the art.
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A single shaft agitate and spin drive for an automatic washer is provided in which a lost motion mechanism or clutch in the form of a plurality of stacked discs is mounted on the agitator shaft, a lower end of the mechanism being driven by the agitator shaft and an upper end of the mechanism driving the basket after a sufficient amount of rotation by the agitator has been inputted to the mechanism. The mechanism absorbs enough rotational motion to allow oscillatory motion of the agitator without transmission of that motion to the basket, but if sufficient rotational motion is input to the mechanism, such as during the spin mode, the mechanism transmits the motion to drive the basket. The amount of rotation absorbed is easily changed by changing the number of discs in the stack.
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BACKGROUND OF THE INVENTION
The present invention relates to a star sensor for use in the attitude control of satellites and, more particularly, to a star sensor using a charge-coupled device (CCD) in its star imaging array.
In one of the conventional techniques of using a CCD, the output of the CCD, after being amplified, is applied to a sample-and-hold circuit for voltage retention. The sustained voltage is then compared with a reference voltage by a voltage comparator. This reference voltage corresponds to the star magnitude, and the sustained voltage, if found to be above the reference voltage, is subjected to analogdigital conversion and supplied to a dataprocessing circuit. At the same time, the picture element (pel) position information (i.e., the coordinates of the star) at this moment is supplied from a coordinate counter, which counts the clock pulses outputted from the CCD driving circuit, to the data processing circuit. The latter circuit stores in a buffer memory the CCD output voltage thereby obtained, which is not below the reference voltage, and its positional information with respect to every pel on the CCD. Then, its picks out the highest among the stored voltages and determines the central position of the star on that basis.
Since all the data regarding the pels which exceed the reference value are stored, the conventional star sensor requires a large-capacity buffer memory, which is costly to manufacture and results in added weight. Furthermore, background light rays entering uniformly into the optical system tend to be sensed and affect star image signals adversely, depending on how high the reference voltage of the voltage comparator is set.
Star sensors using CCDs are described in G. Borghi et al, "STAR DETECTION AND TRACKING USING CCDs", IFAC Automatic Control in Space, 1982, pp. 263 to 269. The proposed star sensor has a star search mode and a star track mode, and has a great advantage in accuracy, but it does have the following problems: it is complex in circuitry because it requires two sets of hardware, one for the search mode and the other for the track mode, and also involves the need for different software arrangements for the two modes. Furthermore, this paper in no way touches on the resolution of background light.
SUMMARY OF THE INVENTION
An object of the present invention, therefore, is to provide a CCD-based star sensor which requires a buffer memory of small capacity.
Another object of the invention is to provide a CCD-based star sensor capable of accurately determining the central position of the stage image even if background light rays overlap into the star image signals.
According to the invention, there is provided a star sensor comprising: charge-coupled device (CCD) means for detecting the light rays of a star; means for filtering the outputs of the CCD means; means for detecting the point where the voltage of the output of the filtering means is equal to a predetermined level; and means responsive to the output of the detecting means and of the CCD means for computing the brightness and position of the star.
BRIEF DESCRIPTION OF DRAWINGS
Other objects, features and advantages of the present invention will become more apparent from the detailed description hereunder taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a schematic block diagram of a star sensor according to the invention;
FIG. 2 outlines the composition of a CCD contained in the detector of the star sensor shown in FIG. 1;
FIGS. 3A to 3K are waveform diagrams illustrating the operation of the CCD shown in FIG. 2;
FIG. 4 is a block diagram illustrating one preferred embodiment of the star sensor of the invention;
FIGS. 5A to 5D are waveform diagrams illustrating the operation of the star sensor shown in FIG. 4;
FIG. 6 is a block diagram illustrating another preferred embodiment of the star sensor according to the invention;
FIG. 7 is a mapping plan of the CCD shown to describe the star sensor of FIG. 6;
FIGS. 8A to 8F are waveform diagrams showing the star sensor of FIG. 6; and
FIGS. 9A and 9B are mapping plans of the CCD shown to describe the star sensor of FIG. 6.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1, an optical element 1 focuses rays of light from a star, and supplies them to a detector section 2. Detector section 2 converts the focused light rays into a focused star image signal, and supplies it to a data processing circuit 3. On the basis of the supplied data, the circuit 3 calculates the brighness and position of the star. The result of this calculation enables the determination and control of the attitude of the satellite.
To facilitate understanding of the present invention, the operation of a CCD will be briefly explained with reference to FIGS. 2 and 3A to 3K before describing the invention in more detail. The CCD illustrated in FIG. 2 comprises a photoelectric converter section 4 including a plurality of columns of CCD's for converting light rays into an electric charge corresponding to the intensity of the light rays and for storing the charge. A transfer electrode 6 transfers the charge thus developed at section 4 to a vertical transfer register 5 in response to a transfer signal φ TG . The charge stored in the transfer electrode 6 is then transferred to a horizontal transfer register 7 in response to transfer clock pulses φ V1 and φ V2 . The charge fed from the horizontal transfer register 7 is provided to an output gate 8 in response to transfer clock pulses φ H1 and φ H2 . An output amplifier section 9, which is composed of the diffusion area 10 and field-effect-transistor (FET) amplifier 11, amplifies the charge from the gate 8 and is reset by a reset signal φ R . The output V OUT of amplifier section 9 is a PAM signal as shown in FIG. 3K. In the figure, V DR and V D represent drive voltages for FETs.
FIG. 3A shows a transfer signal φ TG ; FIGS. 3B and 3C show transfer clock pulses φ V1 and φ V2 ; FIGS. 3D and 3E, the transfer clock pulses φ V1 and φ V2 of FIGS. 3B and 3C on an enlarged scale; FIGS. 3F and 3G, the transfer clock pulses φ H1 and φ H2 ; FIGS. 3H and 3I, the transfer clock pulses φ H1 and φ H2 of FIGS. 3F and 3G on an enlarged scale; FIG. 3J, the reset signal φ R ; and FIG. 3K, the output voltage V OUT .
Referring to FIG. 4, the output signal V 1 of a CCD 12 (See FIG. 5A), after being amplified by an amplifier circuit 13, is supplied to a sample-and-hold circuit 14 to become a signal V 2 (FIG. 5B). The signal V 2 is then caused to pass through a fixed delay circuit 25 and is converted into a digital signal at an A/D converter 19 controlled by a zero-crossing detector circuit 23, which will be described below. The digitized signal is supplied to a multiplexer circuit 20 together with the positional information of the pels at the time this signal was obtained, i.e., the coordinate (position relative to the axis of light beam) information of the star obtained by counting with a clock counter 18 clock pulses from a CCD driver circuit 17. The multiplexer circuit 20 provides in multiplexed form the positioned information of pels supplied from the clock counter circuit 18 and the digital signal supplied from the A/D converter circuit 19. The multiplexed signal is then fed to an on-board data processor circuit 21 at the next stage, wherein prescribed processing is achieved.
Next, a characteristic part of the present invention will be described. A filter circuit 22 comprises a lowpass filter (LPF) and a high-pass filter (HPF) (neither illustrated). From the output signal V 2 coming from the CCD 12 via the sample-and-hold circuit 14, first the LPF provides a signal V 21 shown in FIG. 5B, and then the HPF, the signal V 3 shown in FIG. 5C. The latter is supplied to a zero-crossing detector circuit 23 which detects the zero-crossing point of the output signal V 3 to provide an output V 4 to the A/D converter 19. As is evident from FIG. 5C, the zero-crossing point occurs at a location corresponding to three pels after the pel manifesting the highest output. The output V 4 triggers the A/D converter 19 to convert the signal V 2 , that is delayed by three bits by the delay circuit 25, into a digital signal. Threfore, the signal thus digitized indicates the peak value of the signal V 2 and is supplied to the multiplexer circuit 20.
The output signal V 3 of filter circuit 22 is also supplied to the voltage comparator 24 with which the signal V 3 is compared with a reference voltage that is supplied from a reference voltage generator 16 and corresponds to the predetermined magnitude of a star. When the voltage value of the signal V 3 exceeds the reference voltage, the comparator 24 provides a control signal to enable the clock counter circuit 18 to supply the multiplexer circuit 20 with its output, i.e., the positional information of CCD image.
Thus, the data processor circuit 21 is supplied from the A/D converter 19 with the digitized peak value of one horizontal sequence of pels of the CCD image and from the clock counter circuit 18 with the positional information behind the peak value by three bits. The positional information can be made the information of the peak value by simply counting down or up by the delay the value supplied from the counter circuit 18.
Receiving a peak value and its positional information from every one of the horizontal and vertical sequences of pels, the data processor circuit 21 accurately determines the brightness and position of the star. The quantity of data to be memorized need not be greater than one each of horizontal and vertical sequences around the star image on the CCD. In other words, it is sufficient to store, for instance, 10 pieces of data as in FIGS. 9A and 9B, which will be described later. Furthermore, the control signal from the comparator circuit 24 is generated on the basis of a signal having passed through the filter circuit 22. Therefore, the star image detection is not adversely affected by background light or the dark current fluctuation of the CCD. Background light rays, which are uniformly superimposed on the desired signal, for instance like the dotted lines in FIG. 5A, are removed by the function of the HPF in the filter circuit 22. The dark current fluctuation is also eliminated by the filter circuit 22.
Referring now to FIG. 6, a clock counter circuit 118 and an A/D converter 119, unlike their respective counterparts in the embodiment illustrated in FIG. 4, sequentially supply the star image data and the positional information from time to time, respectively, to a data processor circuit 121 by way of a multiplexer circuit 20. The data processor circuit 121 memorizes a column or a row from the horizontal or vertical sequences of pels of the CCD 12, executes on the basis of this data the same algorithm as the filter circuit 22 and the zero-crossing detector 23 in the embodiment shown in FIG. 4, and thereby detects the brightness and position of the star image.
Next, the operation of the star sensor of FIG. 6 will be described in detail with reference to FIGS. 7 and 8A to 8F. In FIG. 7, which illustrates the image of a star formed on the CCD 12, the addresses of pels in the horizontal (H) direction are designated as H L , H L+1 , H L+2 and so on, and those in the vertical (V) direction, as V K , V K+1 , V K+2 and so on. It is seen that the center of the star image has the address of (H L+2 , V K+2 ). The output level of each pel is represented by S K ,L and so forth. The position and brightness of the star to be determined are the values at (H L+2 , V K+2 ) and S K+2 , L+2, respectively.
They are obtained in the following flow:
(1) The data are edited on the V K line. Thus, the addresses and outputs of pels in FIG. 7 are rearranged as in FIG. 8A. If the input has a uniform background, it is represented by an increase or a decrease of the offset from the "0" level shown in FIG. 8A.
(2) Data are interpolated into the V K line. Thus, as shown in FIG. 8B, the rearranged pels are interpolated between them to provide a suitable function.
(3) The function interpolated into the V K line is transformed into a frequency domain by fast Fourier transform (FFT). Thus, as shown in FIG. 8C, there are obtained in frequency domain a fundamental, harmonics and D.C. components corresponding to a uniform background.
(4) Filtering is achieved in frequency domain. Thus, filtering is so effected as to pass only the fundamental frequency component shown in FIG. 8C. The frequency characteristic of filtering is shown in FIG. 8D. The output after the filtering is illustrated in FIG. 8E.
(5) The output filtered with respect to the V K line is transformed into time domain by inverse fast Fourier transform (IFET). Thus, as shown in FIG. 8F, the waveform in time domain is obtained.
(6) The center of L is determined from the waveform transformed into the time domain. Thus, the zero-crossing point is determined from the waveform of FIG. 8F, and the central position of L is determined. The address L+2 and the level S K , L+2 are memorized.
The processing of the V K line has been described above. The V K+1 , V K+2 . . . lines are similarly processed. FIG. 9A shows the result of the processing of the V K , V K+1 . . . lines.
Next, the processing illustrated in FIGS. 8A to 8F is applied to the H L , H L+1 . . . column in the same way as to the V lines to obtain the result shown in FIG. 9B. On the basis of the crossing points of the broken lines in the results thereby obtained, shown in FIGS. 9A and 9B, the center of the star image focused on the CCD is determined, as illustrated in FIG. 7. The level at this address is also read out.
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A star sensor which includes a charge-coupled device (CCD) for detecting light rays of a star and for producing an output representative of the distribution of the light rays of the star over the CCD. The CCD output is filtered and a detecting circuit is used for finding the points where the output signal voltage of the filter equals a predetermined level. A computing circuit compares the output of the detecting circuit to a reference voltage to locate peak values of the CCD signal. A data processor uses the generated outputs which correspond to the peak values to calculate the brightness and position of the star.
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BACKGROUND OF THE INVENTION
This invention relates to a circuit comprising a frequency-determining element, a clock generator for generating a clock signal and a control circuit coupled to the clock generator for generating a control signal as a function of the magnitude of the voltage on the frequency-determining element and for applying the control signal to the frequency-determining element.
Such a circuit is disclosed in the French Patent Application FR-A 2487607. In this prior art circuit an oscillator is biased by the control signal. A second control signal, which is generated by a phase control loop and causes the oscillator signal to be substantially in synchronism with an incoming synchronizing signal, is superposed on this control signal. Since the substantially constant clock signal is used for biasing the circuit, the clock signal is fairly uniform, independent of variations of the supply voltage, and can be dimensioned such that the frequency of the oscillator is approximately in the middle of the lock-in range of the control loop. To that end the control circuit includes an auxiliary oscillator having a rather high frequency and which is incorporated in a control loop, the auxiliary oscillator being controlled to a substantially constant frequency with the aid of a control signal produced in the said control loop as the result of a phase comparison between the clock signal and a signal derived from the signal of the auxiliary oscillator by frequency division. A proportional portion of the latter control signal is the output signal of the control circuit. From the foregoing it will be obvious that the prior art circuit must be rather complicated.
SUMMARY OF THE INVENTION
An object of the invention has for its object to provide an oscillator circuit of the above-defined type which is of a simpler structure than the prior art circuit. To that end, a circuit according to the invention is characterized in that the control circuit includes a second frequency-determining element for converting the clock signal into a second signal having a constant slope as a function of time and a storage element for the said control signal which depends on the amplitude of the said second signal.
The generator according to the invention can be easily realized and comprises components which are not very critical. In a simple manner the generator can be dimensioned such that variations in response to spread and aging of the components and temperature variations between the components of the control circuit and of the oscillator are compensated.
BRIEF DESCRIPTION OF THE DRAWING
The invention will now be described in greater detail by way of example, with reference to the accompanying drawing, in which:
FIG. 1 is a simplified basic circuit diagram of a circuit according to the invention, and
FIG. 2 is a circuit diagram of a preferred embodiment of a control circuit which forms a part of the circuit in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a basic circuit diagram of a circuit according to the invention. At a first input a phase comparator stage 1 receives an incoming synchronizing signal Sy and at a second input a signal originating from an oscillator 3. Stages, not shown, for example a frequency divider can be present between the output of the oscillator 3 and the second input of the phase comparator stage when the oscillator frequency exceeds the frequency of the synchronizing signal. The phase comparator stage 1 supplies from an output a signal which depends on the phase difference between the input signal of stage 1 and which, after having been smoothed by a loop filter 2, is applied as the first control signal to the oscillator 3 for controlling the frequency and/or the phase of the oscillator signal. In the stable state of the phase control loop formed by elements 1, 2 and 3 the input signals of stage 1 have the same frequency at substantially the same phase.
A clock generator 4 generates a clock signal of a constant clock frequency and applies this clock signal to a control circuit 5. The control circuit 5 supplies a signal which is applied as the second control signal to the oscillator 3. The phase control loop generates the first control signal for the oscillator in the case where the synchronizing signal is present. If the second control signal is now chosen appropriately, the oscillator frequency will be approximately halfway the lock-in range, which is the nominal state.
FIG. 2 shows a more elaborate circuit diagram of the control circuit 5 of FIG. 1. At an input I the control circuit receives the clock signal from the clock generator 4 of FIG. 1. At an output O the control circuit generates an output signal which is applied as the second control signal to the oscillator 3 of FIG. 1. The present synchronizing circuit forms, for example, part of a picture display device, the oscillator 3 then being a line oscillator for the horizontal deflection having a nominal frequency of 15.75 kHz (U.S. televison standard). The oscillator 3 may operate at the line frequency or a multiple thereof. Optionally, the local signal applied to the second input of stage 1 is supplied by a line deflection circuit, which circuit is supplied with a line signal originating from the oscillator. The clock signal is derived from a chrominance subcarrier signal having a nominal frequency of approximately 3.58 MHz. The clock generator 4 is, for example, a frequency divider receives a signal originating from an auxiliary carrier oscillator and which divides the frequency of this signal by 14, from which a clock signal can be obtained with a frequency of approximately 255 kHz.
The clock signal is a square-wave signal and drives controllable switches SW1, SW2 and SW3. The switch SW1 has one side connected to a first reference voltage source Vref1 and its other side to an inverting input of a differential amplifier AMP. In addition, a capacitor C1 is connected to the amplifier inverting input. A controllable current source S1 is connected to the amplifier inverting input via a switch SW2. The capacitor and the current source S1 have their other side connected to ground. The junction point between the switch SW2 and the current source S1 is connected to ground via the switch SW3. The non-inverting input of the differential amplifier AMP is connected to a second reference voltage source Vref2. The output of the amplifier AMP is connected to an input of an amplifier A via a rectifier D. A storage element constituted by a capacitor C2, which has its other end connected to ground, is also connected to said input. The output of the amplifier A is fed back to a control input of the current source S1. The output of the amplifier A also constitutes the output O of the control circuit 5.
When the square-wave clock signal becomes high, the switches SW1 and SW3 become conductive and the switch SW2 is rendered non-conducting, and when the clock signal becomes low, the switches SW1 and SW3 are rendered non-conducting and the switch SW2 becomes conductive.
If the switch SW1 conducts, the first reference voltage Vref1 is present across the capacitor C1. The first reference voltage Vref1 exceeds the second reference voltage Vref2, as a result of which the amplifier AMP supplies a negative output voltage. Because of this negative voltage the rectifier D will not conduct. If the switches SW1 and SW3 become non-conducting, the voltage across the capacitor C1 decreases linearly because the switch SW2 is conducting and the current source S1 withdraws a constant current from the capacitor C1. When the voltage across C1 decreases to below the voltage Vref2, the amplifier AMP supplies a positive voltage and the rectifier D will conduct. A current which recharges the capacitor flows through the capacitor C2, in response to which the voltage across the capacitor and consequently the output voltage of the amplifier A increases. The current source S1 is controlled such that the current thereof obtains a lower value so that the sawtooth-shaped signal across the capacitor C1 reaches the value Vref2 at a later instant than would be the case if the current source S1 were not controlled. As a result thereof the current pulse through the rectifier D is of a shorter duration. This proves that in the stable state of the control loop formed by the elements C1, S1, AMP, D, C2 and A the edge of the sawtooth voltage produced during the time in which the switch SW1 is inhibited reaches the value Vref2 at the instant at which the switch becomes conductive again. At that instant the rectifier D is briefly conducting to compensate for discharging currents, illustrated in FIG. 2 by a current source S2. The sawtooth voltage across the capacitor C1, which has a constant frequency if the frequency of the clock signal of the generator 4 is constant, consequently has a substantially uniform slope as a function of time (see FIG. 2), so that the value of the d.c. voltage at the output O only depends on the values of the elements of the circuit shown in FIG. 2. If these values are constant, then also said voltage is constant. The elements of the circuit can be chosen such that the said voltage is of such a value that the oscillator 3 supplies a signal having the nominal frequency.
It should be noted that the circuit of FIG. 2 can be structured differently to obtain the same result. The control for keeping the voltage across the capacitor C2 constant can alternatively be effected in response to an error signal which depends on the difference between this voltage and a third reference voltage. It should be further noted that in the foregoing description tolerances of the circuit elements and changes caused by temperature fluctuations, aging and such have not been taken into account. This can be explained in the following manner.
For the capacitor C1, which is discharged with the aid of a current source, it holds that the product of the current i1 of the source and the discharging time Δt is equal to the product of the capacitance C1 and the voltage difference ΔW1=Vref1-Vref2 across the capacitor:
i1*Δt=C1*ΔW1 (1)
The time Δt is a given portion of the clock signal period, for example, half the period, so the clock frequency f=1/(2*Δt). The equation (1) can be rewritten to:
i1=C1*ΔW1*2f (2)
The oscillator 3 is of such a structure that the signal generated thereby has a uniform variation as a function of time which is of the same form as the signal at the inverting input of the amplifier AMP. The oscillator 3 consequently is a sawtooth generator having a different frequency than the generator consisting of C1 and S1 and includes a capacitor C3 which is charged and discharged, respectively, between two reference voltage levels Vref1' and Vref2'. For the respective charging and discharging current i2 of the capacitor C3 a value is chosen which is equal to k*i1, wherein, for example, k=1. For the capacitor C3 a similar equation as for the capacitor C1 holds:
i2*Δtosc=C3*ΔWosc (3)
wherein
ΔWosc=Vref1'-Vref2'
and wherein Δtosc is the charging or discharging time of the capacitor C3. The equation (3) can be rewritten to
Δtosc=C3*ΔWosc/i2 (4)
in this example i2=i1; when the value for i1 is substituted in equation (4) it results in:
Δtosc=(C3*ΔWosc)/(C1*ΔW1*2f)=(C3/C1)*(ΔWosc/ΔW1)*(1/(2f)) (5)
The ratio C3/C1 is constant. If, in addition, the capacitors C1 and C3 are integrated in the same integrated circuit, then this ratio has a much narrower tolerance than the capacitances C1 and C3 themselves. The reference voltages Vref1 and Vref2 and the reference voltages Vref1' and Vref2' are chosen such that the ratios of ΔWosc/ΔW1, i.e. (Vref1-Vref2)/(Vref1'-Vref2'), is constant and independent of variations of the separate reference voltages. Since the frequency f of the clock generator is also constant, it follows that the time Δtosc and consequently the nominal frequency of the oscillator 3 is fully determined and is substantially independent of spreads in the components, temperature fluctuations or aging. It should be noted that the capacitance of the capacitor C2 is of no importance in the foregoing. The capacitor C2 must be chosen to have an adequately high value to smooth the signal applied, but it must at the same time be small enough so that it does not respond too slowly to permanent changes.
The control signal at the output O can alternatively be used in other portions of the picture display device, for example, for a circuit for indicating the presence of a line or field synchronizing signal. Such a filter circuit is then used for signal identification purposes and in FIG. 2 is denoted by reference numeral 6. If, for example, the line synchronizing signal Sy is applied to the circuit 6 in FIG. 2, then a signal having the line frequency is supplied. Spreads in this signal are compensated by the signal at the output O in a similar manner to the spreads in the signal originating from the oscillator 3.
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A circuit for generating a control signal includes a frequency-determining element (C3), a clock generator for generating a clock signal and a control circuit coupled to the clock generator for generating a control signal as a function of the magnitude of the voltage at the frequency-determining element and for applying the control signal to the frequency-determining element. The control circuit includes a sawtooth generator having a sawtooth frequency-determining element (C1) for converting the clock signal into a second signal having a constant slope as a function of time, and a storage element (C2) which produces a voltage that depends on the amplitude of the sawtooth signal.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a negative electrode carbon material for a lithium ion secondary battery and to a manufacturing method thereof. More specifically, the present invention relates to a negative electrode carbon material for a lithium ion secondary battery which is manufactured from a rice starch portion as a raw material and has an excellent effect on reducing the raw material cost, and relates to a manufacturing method thereof.
[0003] In the present invention, the term “rice starch portion” indicates a starch portion derived from rice which is called “middle-grade white bran” or “high-grade white bran” and an albumen portion containing a large amount of starch particles.
[0004] 2. Description of the Related Art
[0005] JP-A-2001-266,850 discloses a technology in which rice bran is used as a raw material for a negative electrode carbon material for a lithium ion secondary battery. In this invention, the lees of rice bran obtained after oil is extracted from the rice bran, that is, the pericarp and testa in the rice bran, commonly called “red bran”, are used as a raw material and mixed with a thermosetting resin such as a phenolic resin, and the mixture is calcinated to thereby manufacture a carbon material for a negative electrode.
[0006] However, in the invention disclosed by this publication, as described in examples, the step for extracting oil from rice bran is indispensable. Without it, a large amount of volatile matter other than water floats at the time of calcinating, adheres to the inside wall of a furnace, and generates a bad smell, thus making the method impractical. In addition, the maintenance of an electric furnace after calcinating is necessary and the cost for this is indispensable. Further, a thermosetting resin such as a phenolic resin which is used in combination with rice bran is more expensive than rice bran. As a result, the merit of reducing the cost by using rice bran as one of the vegetable residues cannot be enjoyed.
[0007] Unhulled rice is the seed of a rice plant, and unpolished rice is obtained by removing the hull of this unhulled rice. The unpolished rice is composed of the pericarp, testa, embryo, and albumen, and the albumen is composed of an outer aleurone layer and an inner layer of a starch storing tissue. The pericarp and the testa are also called “red bran”. As for the mass of each tissue of the unpolished rice, from the exterior side, the red bran accounts for 5 to 7%, the embryo accounts for 2 to 3%, and the albumen accounts for 90 to 93% of the total.
[0008] The surface layer of the unpolished rice having a polished rice percentage L of 100 to 91% may be called “red bran layer”, the exterior portion of the albumen having a polished rice percentage L of 91 to 81% may be called “sapio layer”, and the interior portion of the albumen having a polished rice percentage L of 81 to 66% may be called “white bran layer”.
[0009] In general, in the process for polishing unpolished rice, the degree of polishing rice can be expressed by polished rice percentage L. The polished rice percentage L herein refers to the percentage of the mass of polished rice to the mass of unpolished rice as shown by the following expression 1.
Polished rice percentage L (%)=(mass of polished rice÷mass of unpolished rice)×100 (1)
[0010] The polishing percentage refers to the percentage of the mass of grounds to the mass of unpolished rice as expressed by the following expression 2.
Polishing percentage (%)=(mass of grounds÷mass of unpolished rice)×100 (2)
[0011] Further, the mass of unpolished rice is the total of the mass of polished rice and the mass of grounds as expressed by the following expression 3.
Mass of polished rice+mass of grounds=mass of unpolished rice (3)
[0012] Therefore, the following relational expression (4) is always established for the degree of polishing rice.
Polished rice percentage L (%)+polishing percentage (%)=100 (%) (4)
[0013] The polished rice percentage L of rice to be eaten as cooked rice is generally about 92 to 90%. Polished rice having a polished rice percentage L of 70 to 50% is generally used for the brewing of sake, and the quality of sake is generally improved by reducing the polished rice percentage L. A portion having a polished rice percentage L of 90 to 70% (polishing percentage of 10 to 30%) is called “middle-grade white bran”, and a portion having a polished rice percentage L of 70 to 50% (polishing percentage of 30 to 50%) is called “high-grade white bran”.
[0014] As for the above rice bran, the middle-grade white bran and the high-grade white bran are used as fodder and raw materials for confectionery. The development of new applications is desired for the effective use of the rice bran.
SUMMARY OF THE INVENTION
[0015] In view of the above problems of the prior art, the inventors of the present invention have conducted intensive studies on a negative electrode carbon material for a lithium ion secondary battery which is free from problems such as a bad smell at the time of calcinating and the maintenance of an electric furnace, can be produced at a low cost, and has the same or higher performance than that of the prior art products, and a manufacturing method thereof. They have found that the above objects can be attained by obtaining a rice starch portion from unpolished rice and calcinating it, thus accomplished the present invention.
[0016] It is therefore an object of the present invention to provide a negative electrode carbon material for a lithium ion secondary battery which is free from problems such as a bad smell at the time of calcinating and the maintenance of an electric furnace and has the same or higher performance than that of the prior art products.
[0017] It is another object of the present invention to provide a method for manufacturing a negative electrode carbon material for a lithium ion secondary battery which is capable of manufacturing the above negative electrode carbon material for a lithium ion secondary battery at a low cost.
[0018] That is, the present invention provides a negative electrode carbon material for a lithium ion secondary battery which is manufactured by calcinating a rice starch portion obtained by removing the pericarp and testa from unpolished rice.
[0019] Further, the present invention provides a method for manufacturing a negative electrode carbon material for a lithium ion secondary battery, including a first step for obtaining a rice starch portion by removing the pericarp and testa from unpolished rice and a second step for calcinating the rice starch portion.
[0020] In the starch storing tissue of the albumen which is a starch portion derived from rice, in general, one amyloplast is densely filled with 50 to 80 starch particles. As for the size of each starch particle of rice, the diameter of the starch particle is about 6 to 10 μm for a relatively large amyloplast having a long diameter of about 40 μm and about 1 μm for a relatively small amyloplast. In other word, the starch particle of rice is generally as large as 10 μm or less and much smaller than starches derived from other plants. Therefore, by calcinating the starch particles of rice, carbon particles having a small primary particle diameter and a large specific surface area can be obtained and a carbon material suitable for the manufacture of a negative electrode for lithium ion secondary batteries can be manufactured.
[0021] Preferably, the rice starch portion used in the present invention is middle-grade white bran or high-grade white bran obtained by polishing unpolished rice, and the negative electrode carbon material of the present invention has a relatively broad peak at a 2θ of 40 to 50° and a sharp peak at a 2θ of 42 to 44° in its powder X-ray (CuKα) diffraction diagram. When it has a sharp peak at a 2θ of 42 to 44° and this negative electrode carbon material is used to manufacture a lithium ion secondary battery, initial charge/discharge efficiency is improved and the resulting negative electrode shows excellent performance. To distinguish the sharp peak exists at a 2θ of 42 to 44° from noise easily, the A/B ratio of the intensity A of the sharp peak at a 2θ of 42 to 44° to the intensity B of the relatively broad peak at a 2θ of 40 to 50° is preferably 1.2 or more, more preferably 1.4 or more. The half-value width of the above relatively broad peak is preferably 3.5 to 5.5° and the half-value width of the sharp peak is preferably 0.30 to 0.45°.
[0022] The negative electrode carbon material for a lithium ion secondary battery of the present invention is formed from a starch portion composed of starch particles smaller than starch particles derived from other plants. Fine particles constituting the negative electrode carbon material for a lithium ion secondary battery can be made finer even after they are calcinated, thereby making it possible to shorten the distance between particles and make the microstructure finer. Therefore, the microstructure forms a plane (110) and the sharp peak at 42 to 44°. If the fine particles after calcinating can be made finer and the distance between particles can be made short to form a fine structure such as a network structure like hard carbon, a negative electrode for lithium ion secondary batteries can be manufactured from a thinner carbon material. When compared with a negative electrode of the same volume, the number of network structures increases and the capacity of a space which lithium ions easily enter increases owing to the fine microstructure of the carbon material, thus a large capacity can be expected.
[0023] Since a portion containing a large amount of starch particles is used in the negative electrode carbon material for a lithium ion secondary battery of the present invention, as compared with a carbon material obtained by adding a phenolic resin to red bran and calcinating the mixture, the structure after calcinating is fine and the battery characteristics are improved. The negative electrode carbon material of the present invention is advantageous in terms of production cost over a carbon material manufactured from petroleum pitch.
[0024] The method for manufacturing a negative electrode carbon material for a lithium ion secondary battery of the present invention includes a first step for obtaining a rice starch portion by removing the pericarp and the testa from unpolished rice and a second step for calcinating the rice starch portion. Since the pericarp and the testa are removed in the first step, the rice starch portion to be calcinated in the second step does not contain oil, thus a large amount of volatile matter does not float at the time of calcinating. As for the first step for obtaining the rice starch portion, rice bran collected in a step for polishing rice for the manufacture of sake is simply divided into a portion consisting of the pericarp and the testa and the other rice starch portion, thereby making possible the acquisition of a rice starch portion as the by-produced middle-grade white bran or high-grade white bran. Thereby, the raw material cost can be significantly cut. In the above second step, the rice starch portion is calcinated to obtain a negative electrode carbon material for a lithium ion secondary battery having a fine network structure with excellent lithium ion holding properties. The calcinating of the second step can be carried out in an inert gas atmosphere such as nitrogen gas or argon gas.
[0025] The first step preferably includes a sub-step for removing an aleurone layer after the pericarp and the testa is removed from the unpolished rice. The middle-grade white bran contains a partial aleurone layer and an albumen. The high-grade white bran composed of an albumen alone is preferred because the structure of the negative electrode carbon material obtained after calcinating is uniform and fine. However, the cost for acquiring the high-grade white bran is higher than that of the middle-grade white bran, and whether the middle-grade white bran or the high-grade white bran should be used as a raw material or a mixture thereof should be used depends on balance between the cost and the obtained structure.
[0026] Further, the first step is a step for acquiring a rice starch portion corresponding to middle-grade white bran or high-grade white bran obtained when unpolished rice is polished. The second step preferably includes a sub-step for calcinating the rice starch portion corresponding to the middle-grade white bran or high-grade white bran. In this case, the rice starch portion is powdery. The first step can be a step for acquiring a powdery rice starch portion by removing the pericarp and the testa from the unpolished rice. Further, this powdery rice starch portion is molded into a pellet, and the pellet rice starch portion is calcinated. Thus, it is possible to bake the rice starch portion uniformly in a short period of time.
[0027] In the method for manufacturing the negative electrode carbon material for a lithium ion secondary battery of the present invention, it is preferable to: acquire a rice starch portion having a polishing percentage of 7% or more to 65% or less by removing the pericarp and the testa corresponding at least to a polishing percentage of less than 7% (polished rice percentage of more than 93%) in the first step; and bake the rice starch portion in the second step. It is more preferable to: acquire a rice starch portion corresponding to a polishing percentage of 9% or more to 65% or less by removing the pericarp and the testa corresponding at least to a polishing percentage of less than 9% (polished rice percentage of more than 91%) in the first step; and bake the rice starch portion in the second step.
[0028] Further, in the method for manufacturing the negative electrode carbon material for a lithium ion secondary battery of the present invention, it is particularly preferable to: acquire a rice starch portion corresponding to a polishing percentage of 12% or more to 65% or less by removing the pericarp, testa and aleurone layer corresponding at least to a polishing percentage of less than 12% (polished rice percentage of more than 88%) in the first step; and bake the rice starch portion in the second step.
[0029] The lower limit of polishing percentage of the obtained rice starch portion needs to be at least 7% to remove the pericarp and the testa from the unpolished rice, preferably 9% or more to remove the pericarp and the testa from the unpolished rice more completely, particularly preferably 12% or more to obtain a uniform and fine structure of a carbide obtained by removing the aleurone layer. The upper limit of polishing percentage of the obtained rice starch portion is preferably 65% or less because when the polishing percentage is higher than 65%, rice is broken, more preferably 60% or less to obtain the rice starch portion at a low cost, particularly preferably 55% or less.
[0030] In the method for manufacturing the negative electrode carbon material for a lithium ion secondary battery of the present invention, the first step is preferably a step for acquiring bran by-produced in a rice polishing step for the manufacture of sake. When rice is polished up to a polished rice percentage of 35%, a rice starch portion having a polishing percentage of 65% or less can be used as a raw material to be calcinated in the second step. When rice is polished up to a polished rice percentage of 40%, a rice starch portion having a polishing percentage of 60% or less can be used as a raw material to be calcinated in the second step. When rice is polished up to a polished rice percentage of 50%, a rice starch portion having a polishing percentage of 50% or less can be used as a raw material to be calcinated in the second step. When rice is polished up to a polished rice percentage of 65%, a rice starch portion having a polishing percentage of 35% or less can be used as raw material to be calcinated in the second step.
[0031] In the method for manufacturing the negative electrode carbon material for a lithium ion secondary battery of the present invention, the second step preferably includes: a sub-step for precalcinating the rice starch portion to thereby obtain a precalcinated product; a sub-step for grinding the precalcinated product into a ground product; and a sub-step for post-calcinating the ground product at a temperature higher than the temperature of the precalcinating step. The rice starch portion can be uniformly calcinated by performing the second step in such a manner, therefore a negative electrode carbon material for a lithium ion secondary battery having excellent powder characteristics can be obtained. In the grinding sub-step, the precalcinated product is ground into particles each having an average diameter of, for example, 5 μm or more to 40 μm or less.
[0032] In the method for manufacturing the negative electrode carbon material for a lithium ion secondary battery of the present invention, the second step can be, for example, a step for calcinating the rice starch portion at 500 to 2,700° C. for 0.5 to 50 hours. In the second step, the precalcinating sub-step is preferably a sub-step for calcinating the rice starch portion at 500 to 1,000° C. for 0.5 to 10 hours, and the post-calcinating sub-step is preferably a sub-step for calcinating the ground product at 700 to 1,600° C. for 0.5 to 50 hours. The post-calcinating sub-step is more preferably a sub-step for calcinating the ground product at 1,100 to 1,400° C., particularly preferably the sub-step for calcinating the ground product at 1,200 to 1,300° C.
[0033] The powder X-ray (CuKα) diffraction diagram of the negative electrode carbon material for a lithium ion secondary battery can have a relatively broader peak at a 2θ of 40 to 50° and a sharper peak at a 2θ of 42 to 44° when the rice starch portion is calcinated at 1,100 to 1,400° C. for 0.5 to 50 hours.
[0034] According to the method for manufacturing the negative electrode carbon material for a lithium ion secondary battery of the present invention, working properties are excellent because volatile matters rarely float at the time of calcination as the pericarp and the testa are removed from unpolished rice, and the raw material cost can be cut as a starch portion derived from rice obtained as a by-product in the manufacture of sake is used. Therefore, the working properties and cost can be improved as compared with the prior art in which a mixture of red bran and a phenolic resin is calcinated. The performance of the obtained negative electrode carbon material for a lithium ion secondary battery can be made equal to or higher than that of the prior art because the pericarp portion is removed. Further, the raw material cost can be reduced because a starch portion derived from rice obtained as a by-product in the manufacture of sake is used, and volatile matters rarely float at the time of calcinating because the testa is removed from unpolished rice. Therefore, working properties are excellent and the total production cost of the negative electrode carbon material for a lithium ion secondary battery can be greatly cut.
[0035] Further, as a rice starch portion having relatively small starch particles is used in the method for manufacturing the negative electrode carbon material for a lithium ion secondary battery of the present invention, the micro-structure of the negative electrode carbon material for a lithium ion secondary battery can be made finer after calcinating compared with a negative electrode carbon material for a lithium ion secondary battery obtained by calcinating a starch portion derived from other plant, thereby making it possible to form a thinner and smaller negative electrode for secondary batteries. As a result, the charge/discharge capacity per unit volume can be increased.
[0036] A red bran portion out of rice bran is apt to change in composition depending on the producing district of the used unpolished rice, climate changes, the harvest time, etc., and the quality control of the obtained negative electrode carbon material for a lithium ion secondary battery is difficult. In contrast to this, a component derived from a raw material rarely changes and quality control is easy because a red bran portion out of rice bran is removed in the method for manufacturing the negative electrode carbon material for a lithium ion secondary battery of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] FIG. 1 is an X-ray diffraction diagram of a negative electrode carbon material for a lithium ion secondary battery according to Example 1 of the present invention.
[0038] FIG. 2 is an X-ray diffraction diagram of the negative electrode carbon material according to Example 8.
DETAILED DESCRIPTION OF THE INVENTION
[0039] Embodiments of the present invention will be described hereinafter.
Examples 1 to 13
[0000] (Step for Acquiring a Rice Starch Portion)
[0040] 600 kg of unpolished rice was polished for 28 hours with a rice polishing machine for brewing (HS-15 CNC of Chiyoda Co., Ltd.) to obtain polished rice for sake having a polished rice percentage L of 50%. At this point, about 60 kg of a rice starch portion corresponding to middle-grade white bran (L=85 to 75%, polishing percentage of 15 to 25%) was obtained by removing a red bran layer (L=100 to 91%) and a sapio layer (L=91 to 85%) (Examples 1 and 2). Similarly, a powdery rice starch portion corresponding to middle-grade white bran (L=80 to 70%, polishing percentage of 20 to 30%) was obtained by removing a red bran layer and a sapio layer (L=100 to 80%) (Example 3). A powdery rice starch portion corresponding to middle-grade white bran (L=90 to 70%, polishing percentage of 10 to 30%) was obtained by removing a red bran layer and a sapio layer (L=100 to 90%) (Examples 4 to 9). Similarly, a powdery rice starch portion corresponding to high-grade white bran (L=65 to 50%, polishing percentage of 35 to 50%) was obtained (Examples 10 and 11). Powdery rice starch portions each corresponding to middle-grade white bran and high-grade white bran (L=85 to 50%, polishing percentage of 15 to 50%) was obtained (Examples 12 and 13). About 5 mass % of water was sprayed over each of the rice starch portions. Then, each of the mixtures was mixed and stirred, was molded into a pellet having a diameter of 3 mm and a length of 3 mm with a granulating machine (Desk Pelleter, F20/330), and dried at 70 to 80° C. for 5 minutes.
[0000] (Baking Step)
[0041] Each of the obtained pellet rice starch portions was precalcinated in a rotary kiln in a nitrogen gas atmosphere at 450 to 900° C. for 0.4 to 9 hours. Thereafter, the precalcinated product was ground to obtain a ground product having an average particle diameter of 20 to 30 μm, and this ground product was put into a crucible and post-calcinated at 650 to 2,700° C. for 0.45 to 48 hours to obtain a negative electrode carbon material for a lithium ion secondary battery. Those conditions are shown in Table 1.
[0042] An X-ray diffraction diagram of the negative electrode carbon material for a lithium ion secondary battery (Example 1) obtained by post-calcinating at 1,200° C. for 5 hours out of those is shown in FIG. 1 . The X-ray source is CuKα (40 kV, 30 mA), the width of a divergence slit was ½ deg., the width of a scattering slit was ½ deg., and the width of a light receiving slit was 0.15 mm. A Kβ filter was used to measure at a scanning range of 10 to 90°. The horizontal axis of the obtained X-ray diffraction diagram shows 2θ(°) and the vertical axis shows the detected intensity (cps). As a result, the carbon material has a relatively broad peak at a 2θ of 40 to 50° and a sharp peak at a 2θ of 42 to 44°. More specifically, the half-value width of the relatively broad peak at a 2θ of 40 to 50° (peak top is at a 2θ of 44°) was 4.60 and the height of the peak was 24 cps. The half-value width of the sharp peak at a 2θ of 42 to 44° (peak top is at a 2θ of 42.9°) was 0.36° and the height of the peak was 46 cps. The ratio of the intensity of the sharp peak to the intensity of the broad peak was 1.92.
TABLE 1 Polishing Precalcinating Post-calcinating percentage of raw Temperature Time Temperature Time Sample No. Raw material material (%) (° C.) (h) (° C.) (h) Example 1 Middle-grade white bran 15-25 700 5 1,200 5 Example 2 Middle-grade white bran 15-25 800 8 1,300 5 Example 3 Middle-grade white bran 20-30 700 5 1,200 0.6 Example 4 Middle-grade white bran 10-30 900 9 1,550 5 Example 5 Middle-grade white bran 10-30 700 4 1,000 5 Example 6 Middle-grade white bran 10-30 550 8 750 10 Example 7 Middle-grade white bran 10-30 900 1 2,700 1 Example 8 Middle-grade white bran 10-30 900 1 1,650 5 Example 9 Middle-grade white bran 10-30 450 0.4 650 5 Example 10 High-grade white bran 35-50 800 2 1,200 5 Example 11 High-grade white bran 35-50 900 3 1,300 0.45 Example 12 Middle-grade white bran + High- 15-50 950 1 1,300 5 grade white bran Example 13 Middle-grade white bran + High- 15-50 700 6 1,650 1 grade white bran Comparative 75% of red bran + 25% of 0.5-6 800 2 900 5 Example 1 phenolic resin Comparative 75% of red bran + 25% of 0.5-6 900 1 1,300 10 Example 2 phenolic resin Comparative 75% of red bran + 25% of 0.5-6 900 1 1,550 10 Example 3 phenolic resin
[0043]
TABLE 2
Adhesion of
volatile
Half-value
Ratio of
Initial charge
Initial
mattersduring
Raw material
Existence
width (*)
peak
capacity (mAh/g)
Efficiency
Discharge
Sample No.
calcinating
cost
of peak (#1)
Broad
Sharp
intensity (#2)
Charge
Discharge
(%)
Performance
Example 1
Small
Inexpensive
Present
4.6
0.36
1.92
111.4
78.3
70.3
⊚
Example 2
Small
Inexpensive
Present
3.9
0.41
2.31
112.5
82.3
73.2
⊚
Example 3
Small
Inexpensive
Present
4.0
0.32
1.35
115.2
80.8
70.1
⊚
Example 4
Small
Inexpensive
Absent
4.2
—
0
111.7
73.0
65.4
◯
Example 5
Small
Inexpensive
Absent
3.8
—
0
110.9
73.4
66.2
◯
Example 6
Small
Inexpensive
Absent
3.5
—
0
111.8
73.2
65.5
◯
Example 7
Small
Inexpensive
Absent
5.2
—
0
109.5
67.3
61.4
Δ
Example 8
Small
Inexpensive
Absent
3.6
—
0
110.3
67.8
61.5
Δ
Example 9
Small
Inexpensive
Absent
4.1
—
0
97.6
55.8
57.2
Δ
Example 10
Small
Slightly
Present
4.0
0.36
2.01
116.1
86.0
74.1
⊚
expensive
Example 11
Small
Slightly
Absent
3.8
—
0
114.3
71.2
62.3
Δ
expensive
Example 12
Small
Slightly
Present
4.8
0.41
1.98
111.7
80.6
72.2
⊚
expensive
Example 13
Small
Slightly
Absent
4.6
—
0
110.6
68.7
62.1
Δ
expensive
Comparative
Large
Expensive
Absent
3.6
—
0
98.6
53.9
54.7
Δ
Example 1
Comparative
Large
Expensive
Absent
4.0
—
0
100.1
58.6
58.5
Δ
Example 2
Comparative
Large
Expensive
Absent
3.7
—
0
96.2
56.2
58.4
Δ
Example 3
(#1): sharp peak detected at a 2θ of 42 to 44° within a relatively broad peak at a 2θ of 40 to 50°
(#2): A/B ratio of the intensity A of the sharp peak to the intensity B of the broad peak
[0044] The negative electrode carbon materials for lithium ion secondary batteries of Examples 2, 3, 10 and 12 each had a relatively broad peak at a 2θ of 40 to 50° and a sharp peak at a 2θ of 42 to 44° like Example 1. However, the negative electrode carbon materials for lithium ion secondary batteries of Examples 4 to 9, 11 and 13 each had a relatively broad peak at a 2θ of 40 to 50°, but the half-value width of a peak at a 2θ of 42 to 44° was less than 0.30° and the A/B ratio of the intensity A of this peak to the intensity B of the broad peak was less than 1.2. Therefore, it could not be distinguished from noise (Table 2). An X-ray diffraction diagram of the negative electrode carbon material of Example 8 is shown in FIG. 2 .
[0045] In Table 1, the negative electrode carbon material for a lithium ion secondary battery of Example 7 which was post-calcinated at 2,700° C. had a graphite structure. The other negative electrode carbon materials for lithium ion secondary batteries had an amorphous-based hard carbon structure.
[0046] Thereafter, secondary batteries each including lithium manganate LiMn 2 O 4 as a positive electrode active substance were manufactured by using those negative electrode carbon materials for lithium ion secondary batteries in accordance with the following procedure.
[0000] (Manufacture of Negative Electrode)
[0047] Each of the above negative electrode carbon materials for a lithium ion secondary battery and polyvinylidene fluoride (binder) were mixed together uniformly in an N-methylpyrrolidinone solvent in a mass ratio of 91:9. Each of the mixtures was applied to both surfaces of a 14 μm-thick copper foil (assembly of negative electrodes) to a thickness of about 80 μm and dried to manufacture a sheet-like negative electrode. Those negative electrodes were cut into a 1.48 cm×13.0 cm piece, respectively.
[0000] (Manufacture of Positive Electrode)
[0048] Commercially available lithium manganate LiMn 2 O 4 (positive electrode active substance, average particle diameter of 10 μm), acetylene black (conducting agent), and polyvinylidene fluoride (binder) were mixed together in N-methylpyrrolidone in a mass ratio of 89:6:5. This mixture was applied to both surfaces of a 15 μm-thick aluminum sheet (assembly of positive electrodes) to a thickness of about 130 μm and dried to manufacture a sheet-like positive electrode. This positive electrode was cut into a 14.3 cm×12.9 cm piece.
[0000] (Preparation of Non-Aqueous Electrolyte)
[0049] LiPF 6 was dissolved in a mixed solvent of ethylene carbonate (EC) and dimethyl carbonate (DMC) in a mass ratio of 50:50 to a concentration of 1 mol/L to prepare a non-aqueous electrolyte.
[0000] (Separator)
[0050] A commercially available porous stretched polypropylene sheet (UP3025 manufactured by Ube Corporation) was used as a separator. This separator was cut into a 14.8 cm×12.8 cm piece.
[0000] (Assembly of Battery)
[0051] A laminate composed of the positive electrode, the negative electrode, and the above separator sandwiched between the electrodes was the basic structure of a test battery. The laminate was immersed in the prepared non-aqueous electrolyte for 10 minutes to impregnate the porous stretched polypropylene sheet with the non-aqueous electrolyte to thereby assemble a lithium ion secondary battery. Lead wires were attached to the assemblies of the positive electrode and the negative electrode, respectively, to carry out a charge/discharge cycle test at a constant current at 30° C. In the charge/discharge test, the initial charge/discharge capacity was measured using a charge end voltage of 4.2 V, a discharge end voltage of 2.9V, and a charge/discharge current density of 1 mA/cm 2 . The results are shown in Table 2 together with the results of initial charge/discharge efficiency (initial efficiency=initial discharge capacity/initial charge capacity×100 (%)). The initial charge/discharge efficiency of the negative electrode carbon material for a lithium ion secondary battery of the present invention was equal to (Δ) or superior (⊚, ∘) to that of the prior art product. The charge/discharge performance of the negative electrode carbon material for a lithium ion secondary battery of the present invention which had a relatively broad peak at a 2θ of 40 to 50° and a sharp peak at a 2θ of 42 to 44° was particularly excellent (⊚).
Comparative Examples 1 to 3
[0052] A red bran layer portion (L=99.5 to 94%, polishing percentage of 0.5 to 6%) was obtained and a phenolic resin was added to the portion in a mass ratio of 75:25 with reference to JP-A-2001-266,850. Like Example 1, a pelleted raw material was precalcinated in a rotary kiln at 800 to 900° C. for 6 hours in a nitrogen gas atmosphere. This precalcinated product was ground to a ground product having an average particle diameter of 20 to 30 μm, and the ground product was placed in a crucible and post-calcinated at 900 to 1, 550° C. for 5 to 10 hours to obtain a negative electrode carbon material for a lithium ion secondary battery (Table 1). A lithium ion secondary battery was assembled in the same manner as in Example 1 to evaluate its charge/discharge performance. The evaluation is shown in Table 2.
Comparative Examples 4 to 6
[0053] Red bran (Comparative Example 4) corresponding to the pericarp and the testa, middle-grade white bran (Comparative Example 5), and high-grade white bran (Comparative Example 6) each exists in the step for polishing unpolished rice were calcinated as samples in an electric furnace. About 5° g of each sample was tested in an Ar gas atmosphere at 1,600° C. for 2 hours. In the case of red bran (Comparative Example 4), volatile matters adhered to the top plate in the electric furnace in an amount larger than 10 mass % of the sample and a very bad smell was generated during calcinating. In the case of middle-grade white bran (Comparative Example 5) and high-grade white bran (Comparative Example 6), the adhesion of volatile matters to the top plate in the electric furnace was less than 2 mass % of the sample. In Comparative Example 4, it took 5 times or more of time and labor to obtain the same amount of a calcinated material as the middle-grade white bran (Comparative Example 5), including low recovery and the time of maintenance of the electric furnace.
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Provided is a negative electrode carbon material for a lithium ion secondary battery manufactured by calcinating a rice starch portion obtained by removing the pericarp and testa from unpolished rice and a method for manufacturing the same. The rice starch portion is preferably middle-grade white bran or high-grade white bran each obtained when unpolished rice is polished. The above negative electrode carbon material preferably has a relatively broad peak at a 2θ of 40 to 50° and a sharp peak at a 2θ of 42 to 44° in its powder X-ray (CuKα) diffraction. According to the present invention, a negative electrode carbon material for a lithium ion secondary battery which has the same quality as the prior art product can be manufactured at a low cost by making effective use of middle-grade white bran or high-grade white bran of rice.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for towing a workpiece. More particularly, the present invention relates to a motorized tractor-towing apparatus of enhanced stability capable of towing an airplane, trailer, or other workpiece.
2. Description of the Related Art
It is frequently necessary to move closely-parked private aircraft, for example, around an airfield or within a hanger. State of the art devices disclose tractors having some capability of moving such aircraft but are unstable, particularly when pulling a heavy workpiece, such as an aircraft. See, for example, U.S. Pat. Nos. 3,819,001 and 3,861,483. Because of their unstable nature, such prior art devices require a stabilizer bar or other mechanism to stabilize it and make it more maneuverable particularly in a towing attitude. However, such additional structure makes the prior art devices particularly difficult to operate in congested conditions such as those frequently found at private airfields.
Other prior art aircraft handling and towing devices are cumbersome and do not provide for sharp turning radii required in maneuvering aircraft about a congested airfield, for example. See U.S. Pat. Nos. 3,049,253; 2,732,088; 2,734,716; 3,038,550; 3,662,911; 4,318,448; and 4,576,245.
Additionally, there exists the need for an enhanced gripper mechanism to attach to the nosewheel or tailwheel of an aircraft in a secure manner and yet operate with a small turning radius. Prior art disclosures, such as U.S. Pat. Nos. 2,874,861 and 2,877,911, do not permit the type of gripping necessary for a tight turning radius operation with enhanced locking capability.
Accordingly, the need exists for an improved towing apparatus for aircraft and other workpieces which is stable even when not towing a workpiece. However, once engaged to either a nosewheel or a tailwheel of an aircraft for example, the device provides for a tight turning radius and is easy to maneuver in forward or reverse.
SUMMARY OF THE INVENTION
The present invention is an apparatus for towing a workpiece, such as an aircraft. The apparatus comprises first and second frames which are in spaced vertical relationship to one another. The frames are attached in such a manner that the first frame rotates relative to the second frame about a common substantially vertical axis. A wheel assembly is supported by the first frame and includes a wheel for rotational movement about a first axis. A motor is used to power the wheel assembly. A handle assembly is attached to the first frame to enable the operator to rotate the first frame relative to the second frame. A gripper assembly is supported by the second frame and offset from the vertical axis. The gripper assembly is positioned on the second frame to engage a workpiece for towing along a second axis which is positioned above or below the first axis by no more than about 30% of the radius of the wheel. In this manner, the present invention provides a low center of gravity and permits the towing axis, or the working axis, to be at or near the rotating axis of the wheel. Thus, a stable towing apparatus is provided which permits the workpiece, such as the nosewheel or tailwheel of an aircraft, to be in close proximity to the wheel of the present invention. Consequently, the turning radius is small.
The present invention may also include a transmission, such as a hydrostatic transmission, positioned between the motor and the wheel assembly to enable the transmission of power from the motor to the wheel on a smooth basis and permit motorized forward and rearward motion of the towing apparatus and the workpiece.
The gripper assembly of the present invention may be used to tow the nosewheel of an aircraft or another wheel of a workpiece. Alternatively, the gripper assembly may be used to tow the tailwheel of an aircraft. If the nosewheel of an aircraft is being pulled, it may be preferable to permit the nosewheel to remain in contact with the ground while the present invention tows the aircraft. In this event, the gripper assembly is supported by the second frame and includes a stationary arm and a pivotal arm. The pivotal arm is rotated relative to the second frame. Once engaged the ends of both the first and second arms compress the axis of a nosewheel to permit a pulling or pushing towing operation by the present invention. The gripper assembly may also include a gas cylinder, for example, positioned between the first and second arms to dampen any movement between the ends of either arm and the nosewheel thereby further securing the first arm relative to the second arm.
In the event the present invention is intended to engage the tailwheel of an aircraft, the gripper assembly may include a tow frame supporting a cradle. The gripper assembly may include means to tilt one end of the tow frame toward the ground enabling the cradle to engage and support the tailwheel. The gripper assembly may also include means for activating the tilt means to lower one end of the tow frame and then raise that same end thereby elevating the tailwheel off the ground and permitting the present invention to tow the aircraft along a towing axis positioned between about 60% of the radius of the wheel of the present invention above the axis of that wheel to about 60% of the radius of that wheel below the rotational axis of the wheel.
Thus, the present invention provides a stable pushing and pulling towing apparatus for a workpiece such as an aircraft that provides for a sharp turning radius, forward and rear motion, and the introduction of substantial power in a forward or rearward direction on a smooth and continuous basis.
The more important features of this invention have been summarized rather broadly in order that the detailed description may be better understood. There are, of course, additional features of the present invention which will be described hereinafter and which will also form the subject of the claims appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to more fully describe the drawings used in the detailed description of the present invention, a brief description of each drawing is provided.
FIG. 1 is an elevation view of the present invention.
FIG. 2 is an elevation view of the present invention from the opposite side shown in FIG. 1.
FIG. 3 is a cross-sectional view of the present invention taken along line 3--3 of FIG. 1.
FIG. 4 is a detailed cross-sectional view taken along line 4--4 of FIG. 3.
FIG. 5 is a bottom view of a portion of the present invention.
FIG. 6 is a view similar to FIG. 5 but in a different operational sequence from that shown in FIG. 5.
FIG. 7 is a top view of an alternate embodiment of a portion of the present invention.
FIG. 8 is an elevation view of the alternate embodiment shown in FIG. 7.
FIG. 9 is a different operational sequence of the alternate embodiment shown in FIG. 8.
FIG. 10 is a top view of another alternate embodiment of a portion of the present invention.
FIG. 11 is a partial top view of a portion of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1-4, the present invention is a towing apparatus 20 having a first frame 22 and a second frame 24. Each frame 22 and 24 is generally rectangular in configuration. In the case of frame 22, it is shown to include longitudinal members 26 and transverse members 28. Second frame 24 includes longitudinal members 30 and a transverse member 32. The present invention also includes a handle assembly 38 having a member 39 which is attached to first frame 22 at pin connection 40. Member 42 serves to brace member 39 to first frame 22.
Referring still to FIGS. 1-4, a motor 44 is attached to, and supported by, first frame 22. Motor 44 may be a conventional internal combustion motor such as a lawnmower motor. In the prototype of the present invention, the motor is a 3.5 horsepower Briggs & Stratton engine, readily commercially available. Alternatively, motor 44 may be another type of motor such as an electric motor or an air motor. Obviously, in such cases the user would need to provide a power source such as electricity or compressed air through a power cord or air hose up to motor 44. In the case of an internal combustion engine as shown, a throttle 46/cable 48 is attached to handle 38 and connects with the throttle setting of motor 44 to power up or down motor 44. The throttle 46/cable 48 assembly is well known to those skilled in the art and is similar to that found on commercially-available lawnmowers.
The present invention also includes a wheel assembly 50 which is rotatably supported within first frame 22. Referring to FIGS. 3 and 4, wheel assembly 50 includes a wheel/tire 52. Axle 54 passes through wheel 52 and is rotatably supported in the preferred embodiment by flanges 56 which are attached to longitudinal members 26 of first frame 22. Each end of axle 54 is held in place by a hub 58 having a lynch pin 60 or other fastener such as a set screw. A sprocket 62 is attached to axle 54 and fixed relative to axle 54 and wheel 52. In this manner, wheel 52 rotates about axle 54, but within first frame 22.
Referring back to FIGS. 1-2, the present invention may include a transmission 64, preferably a hydrostatic transmission, such as that manufactured by the Eaton Corporation, model no. C-250-801. Such a hydrostatic transmission is well known to those skilled in the art and commonly used on riding lawnmowers, garden tractors and off-road vehicles. Such a transmission serves to provide a gradual increase and decrease in power from motor 44 and transfer that power to a wheel assembly 50 in accordance with the present invention as described below. In addition, such a transmission provides for motorized forward and rearward motion.
Power is transferred from motor 44 to transmission 64 by means of a belt 66. As shown in FIG. 2, belt 66 passes around drive pulley 68 of motor 44 and pulley 70 of transmission 64. In accordance with the operation of the present invention as will be described in more detail below, the power output side of transmission 64 is shown in FIG. 1 as drive shaft 72. Shaft 72 is connected to a sprocket 74. A chain 76 is used to drivably engage sprocket 74 with sprocket 62 thereby rotating wheel 52 and driving the present invention.
Referring still to FIGS. 1-4, but in particular FIGS. 1 and 4, second frame 24 is rotatably supported relative to first frame 22 by concentric drums 78 and 80. As shown in FIG. 2 and as noted above, second frame 24 comprises longitudinal members 30. Each longitudinal member 30 is fixedly attached to outer drum 80. Outer drum 80 is a cylindrical member which is vertically supported by, and rotates within, inner drum 78. Drum 78 is securely attached to members 26 of first frame 22. Referring still to FIGS. 1 and 4, it can be seen that outer drum 80 is supported vertically by shoulder 82 of inner drum 78. Thus, second frame 24 can rotate relative to first frame 22 since outer drum 80 can rotate about inner drum 78 about a full 360°. If desirable, second frame 24 may be locked to first frame 22 by a bracket 84 which is pivotably attached at connection 86 to first frame 22. When it is desirable to permit the rotation of the first frame 22 relative to the second frame 24, in accordance with the operation of the present invention as described below, the operator pulls knob 88 upwardly displacing cable 91 and thereby pivoting bracket 84 about connection 86. Thus, bracket 84 releases first frame 22 relative to second frame 24 enabling the rotational movement of first frame 22 relative to second frame 24.
Referring still to FIGS. 1 and 2 and now FIGS. 5 and 6, the present invention also includes a gripper assembly 90 which is used to engage a workpiece. In the case of FIGS. 1-6, the workpiece as shown in phantom lines is a wheel 92, such as the nosewheel of an aircraft. Obviously, it will be apparent to one skilled in the art that wheel 92 may be the wheel of a workpiece other than an aircraft. Gripper assembly 90 comprises a first arm 94 and second arm 96. Referring to FIG. 5 (which is a bottom view looking upwardly), first arm 94 is fixedly attached to second frame 24. First arm 94 includes a longitudinal member 97 which is shown bolted to longitudinal member 30 of second frame 24. A sleeve 100 is attached at one end to member 97 and a pin 98 is adapted to pass through sleeve 100. Pin 98 is bolted by screw 102 to sleeve 100. A hub 104 is attached at one end of pin 98. Hub 104 includes a recess and is selected in size to pass over the axle or wheel hub 106 of nosewheel 92.
Referring still to FIG. 5, second arm 96 of gripper assembly 90 is pivotably connected to frame 24 at pin connection 108. The second arm 96 also includes a hub 126/pin 128 arrangement similar to that described earlier with respect to hub 104/pin 98 of first arm 94. Again, hub 126 engages wheel hub 130 of nosewheel 92. A linkage assembly 110 supported by second frame 24 is used to pivotably rotate second arm 96 relative to second frame 24. Linkage assembly 110 includes a lever arm 112 attached at one end to pin connection 108 and at its other end 114 to rod 116. Rod 116 is in turn pivotably connected to handle 118 at connection 120. Handle 118 is pivotably connected and supported by bracket 124 at pin connection 122. Bracket 124 is welded directly to drum 80 as are longitudinal members 30 of second frame 24. The selection of the length of bracket 124 from drum 80 to pin connection 122 is such that when handle 118 is rotated about pin connection 122 to the closed position as shown in FIG. 6, an over-the-center locking action occurs which prevents handle 118 from being prematurely released except by the operator physically moving handle 118 back to the position shown in FIG. 5. This results in the locking of nosewheel 92 relative to said second frame 24. The gripper assembly 90 may also include a dual-acting gas cylinder 132 which serves to provide compressive resistance in either direction. It is attached at one end 134 to second frame 24 and at its other end 136 to lever arm 112. When handle 118 is rotated to the position shown in FIG. 6 enabling the engagement of second arm 96 against hub 130 of wheel 92, shaft 138 of gas cylinder 132 is extended thereby resisting any movement of second arm 96 relative to second frame 24 as may be caused by any jarring or bouncing movement of nosewheel 92. Yet cylinder 132 serves to permit extreme movement of the end of second arm 96 at hub 126 which may occur if nosewheel 92 hits a pothole or other obstruction on the airfield while being towed. This permits the emergency release of the nosewheel 92 without damaging the nosewheel axle or nosewheel undercarriage assembly.
Referring back to FIG. 2, as discussed above transmission 64 receives its input power from belt 66. Transmission 64 provides forward or rearward direction of the present invention by placement of lever 142 in a forward or rearward direction as discussed herein. This is the mechanism most commercially available hydrostatic transmissions use to shift the direction of rotation of its drive shaft. The Eaton model employed in the prototype of the present invention provides for forward or rearward motion by shifting the rotation of drive shaft 72 from a clockwise revolution to a counterclockwise revolution, depending on the orientation of lever 142.
Referring to FIGS. 2 and 11, handle linkage assembly 140 includes a handle 144 which enables the operator to pull up on either side of handle 144 activating the forward and rearward direction of the present invention in accordance with the foregoing description. Handle 144 is pivotably bolted at connection 146 to member 39 and to a transverse member 147. Member 147 is pivotally connected to link 148. Link 148 is in turn connected to a link 150 through a triangular plate 152. Link 150 is pivotably connected to rod 153, and rod 153 connects to lever 142.
Referring to FIG. 2, the present invention also includes a mechanism to return handle 144 to a centered position as shown in FIGS. 2 and 11. That mechanism is shown in FIG. 2 as centralizer system 151. Link 150 is also pivotally attached at connection 154 to member 155. Member 155 is pivotally connected to a vertical member 157 (FIG. 3) at pin connection 159. Vertical member 157 is fixed to first frame 22. In this manner, member 155 pivots about connection 159 as handle 144 is pulled. Centralizing system 151 also includes a camming member 162 which is fixedly attached at connection 164 to vertical member 157. Camming member 160 pivots at connection 164 and is restrained at its other end by spring 170. In this manner, when either end of handle 144 is pulled and released, the notched portion 161 of camming member 162 serves to return member 155 to the vertical position as shown in FIG. 2. This then serves to return link 150 to its neutral position and also handle 144 to the neutral position as shown in FIG. 11.
In addition to the centralizer system 151 shown in FIG. 2, a tensioner system 163 is also shown in FIG. 2 which serves to ensure adequate tension is maintained on belt 66. This is achieved through a pulley 168 which is supported by member 166. Member 166 is in turn pivotally connected to vertical member 157, and the other end of member 166 is forced in a downward position by compression spring 172. Pulley 168 is urged against the top of belt 66 to ensure that belt 66 remains tight against both pulleys 68 and 70.
The operation of transmission 64 to drive the present invention is as follows. When the operator pulls up or squeezes the right hand portion of handle 144 as shown in FIG. 11, links 148 and 150 are advanced forwardly. This in turn advances rod 153 and lever 142 forward. Advancement of lever 142 forward causes the rotation of drive shaft 72 (see FIG. 1) of the Eaton transmission selected to rotate in a clockwise direction. This in turn causes the clockwise rotation of sprocket 62 which advances the present invention forward. Similarly, when the operator pulls up on the left hand portion of handle 144 as shown in FIG. 11, links 148 and 150 and rod 153 are advanced rearwardly which in turn causes lever 142 to move to the right as shown in FIG. 2. This causes the Eaton transmission to rotate drive shaft 72 in a counterclockwise direction providing for rearward motion of the present invention. Thus, whether the operator is pulling up on the left or right hand portion of handle 144 will determine whether the present invention moves in a forward or rearward direction. If the operator is not pulling up on either portion of handle 144, the lever 142 remains in a neutral position as shown in FIG. 2 due to the centralized system 151 and sprocket 74 of transmission 64 does not rotate.
Referring now to FIGS. 7-10, alternate embodiments of the gripper assembly are shown. Gripper assembly 290 is intended to be used on a workpiece such as the tailwheel of an aircraft. In the case of an aircraft which has a tailwheel (also known as a "tailtragger"), there must be sufficient horizontal distance from the tailwheel of the aircraft to the end of its rudder to clear the towing apparatus. Thus, gripper assembly 290 includes longitudinal members 294 and 296. Unlike the preferred embodiment of gripper assembly 90, longitudinal members 294 and 296 do not pivot relative to one another. Rather, they are bolted to longitudinal members 30 of second frame 24 by bolts 295. While lever arm 112 and rod 116 of locking assembly 110 are shown in FIG. 7, they are not used. Longitudinal members 294 and 296 are held fixed relative to one another by cross members 298. A cradle 300 is provided having members 301, 302, 303. Cradle 300 is used to support the tailwheel 292 of the aircraft, or similar workpiece. Members 294 and 296 include apertures 305. Pins are provided at each end of member 302 and are adapted to fit within corresponding apertures 305 enabling the operator to select the size of opening 310 so as to accommodate a particular size tailwheel 292.
Referring still to FIGS. 7 and 8, assembly 290 includes sled 312 having longitudinal members 314 adapted to slide relative to members 294 and 296. Sled 312 supports a hydraulic jack 316 which is in fluid communication by hose 315 to a hydraulic ram 318. Members 320 are provided which connect at one end 321 to a flange 322 of each member 314. The other end of each member 320 is pivotally connected to a rotating arm 324. A wheel 326 is attached to one end of each arm 324. Each arm 324 is pivotally supported by a member 294 or 296 at pin connection 327.
In the operation of this alternate embodiment, the operator releases all pressure from hydraulic jack 316 which permits sled 312 to slide to the left as shown in FIG. 7. This results in the pivotal movement of wheel 326 about pin connection 327, thereby lowering end 400 of gripper assembly 290 as seen in FIG. 9. In this lowered position, the operator may advance the present invention under a tailwheel 292 into space 310 defined by cradle 300. The operator then pumps handle 317 of jack 316 introducing hydraulic pressure into ram 318 and advancing piston 319 to the right as shown in FIG. 7. Such movement of piston 319 to the right causes sled 312 also to move to the right. This causes the pivotal movement of wheels 326 in a clockwise direction about connection 327 until an elevated position is achieved as shown in FIG. 8. The present invention may then be used to tow the aircraft as described below in more detail below.
Referring to FIG. 10, an alternate embodiment of gripper assembly 292 as seen in FIG. 7 is depicted. In this alternate embodiment, gripper assembly 292' includes a mechanical linkage assembly 401 in place of hydraulic jack 316/hydraulic ram 318 as shown in FIG. 7. Linkage assembly 401 includes a handle 402 pivotally attached to sled 312 at pin connection 404. Handle 402 is connected to member 406 at connection 407. The other end of member 406 is attached to a cross member 298. Thus, rather than pumping a handle 317 to displace a piston 319 and move sled 312 as discussed above with respect to FIGS. 7 and 8, the operator rotates handle 402 about pivot connection 404. If handle 402 is in the position shown by solid lines in FIG. 10, the end 400' of gripper assembly 292' is in the position shown in FIG. 9. Once the operator has positioned the present invention under a tailwheel within cradle opening 310' as discussed above, the operator rotates handle 402 to the position shown by phantom lines in FIG. 10. This causes the advancement of sled 312' to the right as shown in FIG. 10 and elevates wheels 326' to the position shown in FIG. 8. The operator would then be in the position of moving the aircraft in accordance with the present invention as described below.
OPERATION OF THE PRESENT INVENTION
In the operation of the present invention, the operator starts motor 44. The throttle would be placed initially in an idle position and handle 144 would be in a neutral position as seen in FIG. 11. As noted above, the present invention provides that wheel assembly 50 is fixed relative to first frame 22, but can rotate about a first axis 501 defined by axle 54. Similarly, outer drum 80 rotates relative to inner drum 78 about a common substantially vertical axis 502 which, for purposes of FIG. 1, is shown as passing through the center of axle 54 of wheel 52 because wheel assembly 50 is positioned in the center of drums 78/80. However, it is not essential that axis 502 intersect axle 54 for the successful operation of the present invention.
If gripper assembly 90 is used, the operator throttles up motor 44 using throttle 46. If the operator wished to move the present invention in a forward direction, the operator would squeeze the right hand portion of handle 144 thereby advancing lever 142 forward. Since lever 142 is moved in a forward direction, drive shaft 72 rotates in a clockwise direction which therefore rotates sprocket 62 in a clockwise direction and moves the present invention forward. To move the present invention in reverse, the operator squeezes the left-hand portion of handle 144 which moves lever 142 rearward and causes the counterclockwise rotation of drive shaft 72.
Preferably, bracket 84 remains in the locked position as shown in FIG. 1 while the present invention is being maneuvered about in a non-towing mode. However, when it is time to attach gripper assembly 90 to a workpiece, knob 88 is rotated upwardly pivoting bracket 84 about bolt connection 86 thereby permitting relative movement of the first frame 22 relative to the second frame 24.
Referring to FIG. 5, if the preferred embodiment of gripper assembly 90 is used, the operator advances gripper assembly 90 to the position shown in FIG. 5 and engages hub 104 against axle hub 106 of nosewheel 92, for example. At that point, the operator rotates lever 118 into a locked position as shown in FIG. 6 advancing hub 126 of second arm 96 against hub 130 of the nosewheel. In this position, the gripper is fully engaged and gas cylinder 132 provides additional load further securing arm 96 against hub 130. With bracket 84 disengaged, the operator may easily rotate the first frame relative to second frame as shown in FIG. 6. Since wheel 52 has a single point of contact against the ground, it is very easy to rotate the present invention about vertical axis 502. In FIG. 6, first frame 22 has only been rotated about 45° relative to its original position; however, it will be understood by one skilled in the art that first frame 22 may be rotated virtually 360° relative to its original position or with reference to second frame 24. The only obstruction that may limit its rotation is that handle assembly 140 may contact the workpiece. However, except for this limitation, first frame 22 may rotate 360° relative to second frame 24.
Referring back to FIG. 6, once the operator has moved first frame 22 to a particular angle relative to second frame 24, the left portion of handle 144 is pulled upwardly thereby advancing lever 142 to the right as shown in FIG. 2 which is the reverse mode. This means that drive shaft 72 would rotate in a counter clockwise direction which in turn rotates sprocket 62 in a counterclockwise direction and causes the present invention to move in a reverse direction, i.e., it is pulling the aircraft. Moving in a reverse direction enables the operator to advance the workpiece rearwardly and easily maneuver it.
Since the present invention is balanced, it is very easy to operate. As can be seen, the weight of transmission 64 largely balances the weight of the motor 44 about vertical axis 502. In this manner, the present invention is very easy to handle. Additionally, since transmission 64 and motor 44 are close to the ground, the present invention is very stable.
It will be apparent to one skilled in the art that the present invention provides means to simultaneously power and rotate first frame 22 relative to second frame 24 without the need to lift any portion of wheel 52 off the ground. Additionally, the present invention provides a very stable design since it has a low center of gravity. Furthermore, the present invention provides for the towing of a workpiece along an axis 503 (occasionally referred to as a second axis) which is generally co-linear with the point-of-contact of the nosewheel of the workpiece, for example, and the point-of-contact of second frame 24 with drum 80. The present invention provides for the placement of axis 503 proximate axis 501 of wheel 52. By positioning the tow axis 503 proximate axis 501 of wheel 52 enhanced stability is achieved not found in the prior art. For example, in both U.S. Pat. Nos. 3,819,001 and 3,861,483, the prior art devices are unstable due to the significant vertical distance between the towing axis from the rotational axis of the wheel. This creates a large moment which therefore requires a stabilizing system as noted therein.
In the present invention, it has been found preferable to position axis 503 no more than between about 60% of the radius of wheel 52 above to about 60% of the radius of wheel 52 below axis 501. This relationship is shown in FIG. 4 wherein "r" represents the radius of wheel 52 and α represents about 60% of "r". As used herein, the term "wheel" includes the tire. More preferably, α is about 40% of "r", and most preferably, α is about 20% of "r".
Additionally, the present invention provides for a very short turning radius--the distance from the contact point of wheel 52 with the ground and the axle of nosewheel 92. This is also a significant advantage because it permits very sharp turns. In fact, the operator could move first frame 22 90° to 160° off center and then move the aircraft very sharply.
In the use of the alternate gripper assemblies 290 and 290', arms 94 and 96 of gripper assembly 90 are disconnected at bolts 99 as shown in FIG. 5, and arms 294 and 296 are connected to members 30 with bolts 295. If the embodiment shown in FIG. 7 is used, the operator would release pressure within jack 316 allowing sled 312 to slide to the left as shown in FIG. 7 permitting wheels 326 to pivot about connection 327 as seen in FIG. 9. This lowers end 400 of gripper assembly 290. The operator would then advance the present invention by pulling on handle 144 to move the present invention in a forward direction. This would advance end 400 under a tailwheel until it rests within cradle opening 310. At that point, the operator pumps handle 317 moving piston 319 to the right which causes sled 312 to move to the right. Wheels 326 then rotate about connection 327 until in an upright position as shown in FIG. 8. At that point, the operator may move the present invention in a rearward direction as described above and easily maneuver the aircraft about the airfield or within a hanger or other confined space.
If gripper assembly 290' is used as shown in FIG. 10, the operator would simply place handle 402 in the position shown by solid lines. This lowers gripper assembly 290' to the position shown in FIG. 9. Once the tailwheel is positioned within cradle opening 310', the operator moves handle 402 to the position shown by phantom lines in FIG. 10. This elevates gripper assembly 290' to the position shown in FIG. 8. Once again, the operator is then free to operate the present invention as described above.
The foregoing invention has been described in terms of various embodiments. Modifications and alterations to these embodiments will be apparent to those skilled in the art in view of this disclosure. It is, therefore, intended that all such equivalent modifications and variations fall within the spirit and scope of invention as claimed.
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A towing apparatus is disclosed capable of moving aircraft and other workpieces about an airfield or other workspace. The present invention includes a first frame which is rotatable relative to a second frame about a common substantially vertical axis. A wheel assembly is positioned within the first frame and driven by a motor which is also mounted on the first frame. A gripper assembly for engaging the aircraft or other workpiece is attached to the second frame. In this manner, the present invention provides for the towing of aircraft or other workpieces along an axis which is proximate the axis of the wheel assembly. Additionally, it provides for a low center of gravity significantly enhancing the stability and maneuverability of the present invention in a towing attitude or a non-towing attitude.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is the U.S. National Phase Application of PCT International Application No. PCT/EP2012/064709, filed Jul. 26, 2012, which claims priority to German Patent Application No. 10 2011 079 966.4, filed Jul. 28, 2011, the contents of such applications being incorporated by reference herein.
FIELD OF THE INVENTION
The invention relates to a circuit for conducting an electric current between a vehicle battery and an electrical network component which can be connected to the vehicle battery via an electrical element and a vehicle having the circuit.
BACKGROUND OF THE INVENTION
In order to implement measurements of an electric current output to an electrical consumer by an electrical energy source in a motor vehicle, a current sensor can be connected in series between the electrical energy source and the electrical consumer. Such a current sensor is known, for example, from DE 10 2011 078 548 A1, is incorporated by reference.
Current sensors need to be connected in series between the electrical energy source and the electrical consumers.
SUMMARY OF THE INVENTION
An aspect of the present invention consists in improving this connection of the current sensors in series between the energy source and the consumer.
This is achieved by the features of the independent claims. Preferred developments are the subject matter of the dependent claims.
The invention proposes a circuit for conducting an electric current between a vehicle battery and an electrical network component which can be connected to the vehicle battery via an electrical element, which comprises a first electrical line section and a second line section, which is separated from the first line section via a spacer, wherein the line sections are connected to one another via the electrical element.
In the context of the invention, the electrical element can be any desired element which can be connected between the vehicle battery and the electrical network component. Thus, the electrical element can be, for example, the current sensor mentioned at the outset, a filter for improving electromagnetic compatibility (referred to as EMC), a protective diode and/or a temperature sensor, which monitors the ambient temperature for the protection of other electrical elements. In this case, the current sensor can be used for current measurement, charge current regulation, current rise limitation or as a current switch. The current sensor and the corresponding applications can be implemented unidirectionally or bidirectionally.
In the same way, the electrical network component, beside the vehicle battery, can be any desired electrical element such as an electrical energy source in the form of a generator, a socket outlet or another battery or an electrical consumer, such as, for example, a vehicle electrical distribution system or an electric motor.
The cited circuit is based on the consideration that the electrical element could be connected directly between the vehicle battery and the electrical network component. However, this consideration is based on the knowledge that the electrical connection would at the same time also have to take on the mechanical strength between the vehicle battery and the electrical network component. Therefore, with the cited circuit, it is proposed to make electrical contact with the electrical element between the vehicle battery and the other electrical network component via line sections, which are kept at a predefined distance from one another via a spacer. In this way, mechanical loads which are introduced, for example, as a result of heat work, vibrations or other mechanical disturbances onto the circuit can be absorbed by the spacer, with the result that the electrical connection between the line sections and the electrical element is protected against mechanical loads and therefore against mechanical stresses.
By virtue of the cited circuit, the electrical element is electrically connected between the vehicle battery and the other electrical network component permanently and continuously, as a result of which the electrical connection of the vehicle battery and the other electrical network component can be made more reliable.
In a development of the cited circuit, the line sections are interlocked with one another in labyrinth-like fashion. With this development of the cited circuit, the line sections are interleaved with one another in order to achieve a fixed mechanical coupling of the line sections via the spacer and a low level of thermal expansion of the connecting zones between the line sections, which is produced as a result of the now very thin line sections.
In an additional development of the cited circuit, the labyrinth-like interlocking of the line sections is resilient. In this way, the line sections can absorb a remaining proportion of mechanical loads themselves and thus avoid a situation whereby the electrical contact-making points of the electrical element with which electrical contact is to be made via the line sections are also mechanically loaded outside the labyrinth-like interlocking.
In another development of the cited circuit, the spacer is formed from a premold material. A premold material is understood to mean a material which, in a melted state of aggregation, is inserted between the two line sections and then cures between the two line sections. Such premold materials can be, for example, thermosetting plastics and thermoplastics. The premold material makes it possible for the spacer to be formed with very precise dimensions, with the result that the spacer does not brace the two line sections mechanically against one another unnecessarily in a state free of mechanical loads between the two line sections.
In a preferred development of the cited circuit, the premold material envelops a surface of the electrical line sections in such a way that an opening for making electrical contact with the electrical element remains free on the line sections. In this way, further improved mechanical fixing of the electrical line sections and therefore a zone which is even more free of mechanical stresses can be provided for the electrical element and its electrical connection to the electrical line sections.
In another development of the cited circuit, a distance between the first line section and the second line section is dependent on a breakdown field strength of the spacer. The dependence is in particular in this case designed in such a way that the lower the breakdown field strength of the spacer, the greater the distance. Particularly preferably, in this case the distance is selected to be large enough for it to be possible for no electrical flashover to occur between the line sections.
The line sections can consist of copper, aluminum, iron, nickel and alloys thereof. Ostensibly, the temperature coefficient and the thermal conductivity are important in the choice.
In yet another development of the cited circuit, the contact areas on the line sections for making contact with the electrical element are coated. Coating materials which can be selected can include metals or metal alloys used to assist in the electrical contact-making of the electrical element to the corresponding line section. Such metals or metal alloys can be alloys which are based on copper or a mixture of copper and nickel, such as Cu—Ni—SN, Cu—Sn, Cu—Ni—Au, Cu—Ni—Pd—Au or Cu—Ag. The contact areas on the electrical line sections can in this case be cleaned prior to the electrical contact-making, in particular with CO 2 by means of irradiation, with plasma or with a laser. For the contact-making itself, the electrical elements can be applied to the electrical line sections by means of sintering, adhesive bonding or soldering.
In a preferred development of the cited circuit, the cited circuit comprises the electrical element, which is covered by a protective compound. The protective compound, which can also be in the form of glob-top or silicone gel, protects and insulates the electrical element permanently, in particular against moisture and impurities which could result in electrical malfunctioning of the electrical element.
In a particularly preferred development of the cited circuit, the line sections are mounted on a component part mount, referred to as leadframe. A plurality of circuits can be mounted simultaneously on this leadframe and can therefore be mass-produced, wherein the individual circuits ultimately then only need to be separated from one another by being severed.
An aspect of the invention also specifies a vehicle which comprises
a vehicle battery, an electrical network component which is connected to the vehicle battery, and one of the cited circuits, which is connected between the vehicle battery and the electrical network component.
An aspect of the invention also specifies a method for producing a circuit for conducting an electric current between a vehicle battery and an electrical network component which can be connected to the vehicle battery via an electrical element, which comprises the steps of arranging a first electrical line section and a second electrical line section with a gap with respect to one another, introducing a spacer into the gap, and bridging the gap having the spacer with an electrical element, with the result that the electrical element electrically connects the first and second line sections to one another.
The cited production method can be extended by production method steps which analogously realize the features of the cited circuit in accordance with the dependent claims.
The above-described properties, features and advantages of this invention and the way in which these properties, features and advantages are achieved will become clearer and more easily understandable in connection with the description below relating to the exemplary embodiments which are explained in more detail in connection with the drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic view of circuits which are mounted on a leadframe;
FIG. 2 shows a schematic view of one of the circuits shown in FIG. 1 ;
FIG. 3 shows a schematic sectional view of part of the circuit shown in FIG. 2 ;
FIG. 4 shows a schematic sectional view of part of the circuit shown in FIG. 2 ;
FIG. 5 shows a side view of the circuit shown in FIG. 2 , and
FIG. 6 shows an alternative side view of the circuit shown in FIG. 2 .
DETAILED DESCRIPTION
Identical technical elements are provided with the same reference symbols in the figures and are only described once.
Reference is hereby made to FIG. 1 , which shows a schematic view of circuits 2 which are mounted on a leadframe 4 .
In the present embodiment, the circuits 2 are intended to be used for current sensors 6 , yet to be described, which can be connected in series between a vehicle battery (not illustrated in any more detail) and an electrical consumer (not illustrated in any more detail) or between the vehicle battery and an electrical connection (not illustrated in any more detail) for charging the vehicle battery. In FIG. 1 , only some of the current sensors 6 have been provided with a reference symbol, for reasons of clarity. The current sensors 6 are intended to measure the current output by the vehicle battery or the current feeding the vehicle battery, on the basis of which a state of charge of the vehicle battery can be detected, which state of charge can in turn be used for energy management of the vehicle battery.
In the present embodiment, the leadframe 4 has two main rails 8 , from which electrical busbars 10 , also referred to as webs 10 , protrude at right angles, wherein contact is made between said electrical busbars and electrical connections 12 , 14 , 16 (yet to be described) of the circuits 2 . Index holes 18 are formed on the main rails 8 , with it being possible to detect the longitudinal dimensions of the circuits 2 by measurement technology using said index holes in order to transport and separate the circuits 2 in automated fashion.
In FIG. 1 , each circuit has three line sections 20 , 22 , 24 , which are mechanically and electrically isolated from one another by an electrically insulating gap 25 . In FIG. 1 , only the gap 25 of a circuit 2 has been provided with a reference symbol, for reasons of clarity. In this case, one of the electrical connections 12 , 14 , 16 is formed at each line section 20 , 22 , 24 . In the present embodiment, a first of the electrical connections 12 is intended to be connected to the abovementioned vehicle battery, with the result that the first connection 12 will be referred to below as battery connection 12 . A second of the electrical connections 14 is intended to be connected to the abovementioned electrical consumer, with the result that the second connection 14 will be referred to below as consumer connection 14 . A third of the connections 16 is intended to be connected to the abovementioned electrical connection, with the result that the third connection 16 will be referred to below as electrical connection 16 . The line sections 20 , 22 , 24 on which the battery, consumer and electrical connections 12 , 14 , 16 are formed correspondingly will also be referred to below using corresponding nomenclature.
Hereinafter, two current sensors 6 on each circuit 2 bridge two of the line sections 20 , 22 , 24 , with the result that an electrical current can flow either between the battery connection 12 and the consumer connection 14 or between the battery connection 12 and the electrical connection 16 . In this way, a vehicle battery connected to the battery connection 12 can be discharged and possibly charged via the consumer connection 14 and charged and possibly discharged via the electrical connection 16 .
In the present embodiment, the current sensors 6 are mounted on one of the line sections 20 , 22 , 24 and electrical contact is also made between said current sensors and said line section and between said current sensors and the respective further line section 20 , 22 , 24 via a bond 26 . In FIG. 1 , only one of the bonds 26 has been provided with a reference symbol, for reasons of clarity. The current sensors 6 can have any desired design, but the current sensors 6 are particularly preferably in the form of active shunts, which are known from DE 10 2011 078 548 A1. For reasons of brevity, reference is made to this document for further details regarding these active shunts.
Furthermore, the line sections 20 , 22 , 24 can also connect EMC and ESD capacitors 28 and protective switching elements 30 , which can be in the form of, for example, a protective diode, a protective capacitor or a protective varistor. The EMC capacitors are used for filtering undesired signal components from the current to be conducted and thus improve electromagnetic compatibility and resistance to electrostatic discharges. In FIG. 1 , only some of the EMC capacitors 28 and the protective switching elements 30 have been provided with a reference symbol, for reasons of clarity.
Finally, temperature sensors 32 which can be provided for detecting a temperature of the circuit 2 in order to introduce suitable protective measures in the event of overheating of the circuit 2 can be arranged on the battery line section 12 and/or one of the other line sections 14 , 16 . In FIG. 1 only some of the temperature sensors have been provided with a reference symbol, for reasons of clarity. In addition to this monitoring function, the temperature sensors can also be used for characteristic correction of the electrical elements, such as, for example, field-effect transistors contained in the current sensors 6 .
The above-described gap 25 is thus necessary for current measurement, for increasing electromagnetic compatibility (EMC) and resistance to electrostatic discharges (ESD) and for implementing the protective switching elements 30 . It therefore needs to be ensured that the individual line sections 12 , 14 , 16 do not have any electrical contact with one another.
On the other hand, the individual line sections 20 , 22 , 24 also require a certain mechanical hold with respect to one another, however. Otherwise, the bonding wires 26 , the EMC capacitors 28 and the protective switching elements 30 would be subjected to excessively severe mechanical tensile loading, which could release the electrical contact between these elements or damage the elements themselves and could thus render the circuit 2 inoperative. In addition, the line sections 20 , 22 , 24 themselves can also be stressed and transfer these stresses to the electrical elements which are mounted on said line sections, such as the current sensors 6 and the temperature sensors 32 , which in this case could also result in release of the electrical contact-making or damage to the elements themselves.
In order to circumvent these disadvantages, in the present embodiment it is therefore proposed to interlock the line sections 20 , 22 , 24 with one another in labyrinth-like fashion and to embed said line sections in a premold compound 34 , with the result that the premold compound 34 holds together the individual line sections 20 , 22 , 24 in an inflexible manner.
This will be explained in more detail below with reference to FIG. 2 , which shows a schematic view of one of the circuits 2 shown in FIG. 1 without population with elements, such as the current sensors 6 , the bonding wires 26 , the EMC capacitors 28 and the protective switching elements 30 and the temperature sensors 32 .
As can be seen from FIG. 2 , the battery line section 20 has labyrinths 36 , into which the arms 38 engage, which arms are formed correspondingly on the consumer line section 22 and on the current line section 24 . The arms 38 in this case have the same labyrinth-shaped profile as the labyrinth 36 , but are narrower, with the result that the electrically insulating gap 25 remains between the line sections 20 , 22 , 24 . By virtue of the arms 38 engaging in the labyrinths 36 , the line sections 20 , 22 , 24 are interlocked and therefore interleaved in labyrinth-shaped fashion.
In order to maintain the mechanical stability between the line sections 20 , 22 , 24 , at least the gap 25 is cast with the premold compound 34 . In the present embodiment, however, all of the line sections 20 , 22 , 24 are coated with the premold compound 34 , wherein openings 40 remain into which the electrical elements mentioned above and shown in FIG. 1 are inserted and can be brought into contact with the line sections 20 , 22 , 24 . This will be discussed in more detail at a later juncture. In FIG. 2 , only some of the openings 40 have been provided with a reference symbol, for reasons of clarity.
If, in the design shown in FIG. 2 , two of the line sections 20 , 22 , 24 are subjected to tensile or compressive loading with respect to one another, this results in the material of the premold compound 34 in the gap 25 being compressed at one point, while it is spread out at another point. In this way, two different counterforces applied by the premold compound 34 act counter to the tensile or compressive loading, as a result of which the line sections 20 , 22 , 24 are held in mechanically fixed fashion in relation to one another at their relative positions.
As a result of the fact that the premold compound 34 additionally also extends over the surface of the line sections 20 , 22 , 24 , the line sections 20 , 22 , 24 are prevented from rotating inwards, resulting in surface tensions which could then be transferred to the abovementioned elements. Thus, an electrically and mechanically stable circuit 2 is provided which also meets very high demands in terms of reliability, as are expected in automotive engineering, for example.
Reference is made to FIG. 3 , which shows a schematic sectional view of part of the circuit 2 shown in FIG. 2 .
FIG. 3 shows part of the battery line section 12 and the current line section 24 , which are electrically isolated by the gap 25 , wherein the gap 25 is bridged electrically via the current sensor 6 and the bond 26 , with the result that an electrical current can flow between the two line sections 20 , 24 via the current sensor 6 .
In the present embodiment, the current sensor 6 and the bonds 26 are surrounded by a protective compound 42 consisting of a glob-top or silicone gel material, which protective compound protects the current sensor 6 and the bonds 26 from the ingress of moisture and other impurities.
The line sections 20 , 22 , 24 can be encapsulated by injection molding with the premold material 34 , for example, with the result that some of the premold material 34 passes through the gap 25 . Therefore, a relatively small accumulation of premold material 34 is located beneath the bond 26 in the region of the gap 25 , and this accumulation provides additional anchoring for the line sections 20 , 22 , 24 in the premold compound 34 .
Reference is made to FIG. 4 , which shows a schematic sectional view of part of the circuit shown in FIG. 2 , in which electrical contact is made with a protective switching element 32 between the battery line section 12 and the current line section 16 .
As can be seen in FIG. 4 , in the present embodiment, electrical contact is made directly between the protective switching element 32 and the line sections 20 , 24 without a further bond. Therefore, it is necessary to ensure that there is no accumulation of premold material 34 beneath the protective switching element 32 . This can be ensured either by virtue of the fact that the gap is covered during encapsulation by injection molding of the line sections 20 , 24 in the opening 40 or the premold material 34 is removed after encapsulation by injection molding of the line sections 20 , 24 in the opening 40 .
Reference is made to FIG. 5 , which shows a side view of the circuit 2 shown in FIG. 2 encapsulated by injection molding with the premold material 34 , wherein the electrical busbars 10 shown in FIG. 1 are electrically connected to the circuit 2 .
As can be seen in FIG. 5 , the connections 12 , 14 , 16 , of which the battery connection 12 and the consumer connection 14 are shown by way of example in FIG. 5 , can be bent back. In this way, the connections 12 , 14 , 16 can extend mechanically at an angle to the circuit 2 , with the result that the connections do not introduce any mechanical loads, for example as a result of thermal expansion, into the circuit 2 .
FIG. 6 shows an alternative example for the design of the connections 12 , 14 , 16 so as to permit mechanical expansion at right angles to the circuit 2 . In FIG. 6 , the connections 12 , 14 , 16 are folded, as a result of which the connections can be pushed together and can thus themselves absorb mechanical expansions in the direction of the circuit 2 .
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The invention relates to a circuit for conducting an electric current, by an electrical component, between a vehicle battery and an electrical network component that can be connected to the vehicle battery. The circuit includes a first electrical line segment and a second line segment that is separated from the first line segment by a spacer. The line segments are connected to one another by the electrical component.
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TECHNICAL FIELD
[0001] The present invention relates to a system for providing short circuit protection to an electrical circuit that connects a device to a DC power source. In particular, the present invention is considered suitable for removing voltage from the circuit that connects a vehicle starter to a battery during the periods when current is not needed to power the starter.
BACKGROUND OF THE INVENTION
[0002] Motor vehicles, such as cars, marine vessels, trucks and the like almost universally include a battery that is used for engine ignition. The battery is electrically connected to a starter that is used to crank the ignition. Typically, the starter is actuated by a solenoid relay located adjacent the starter. As a result, the conductor that carries current from the battery to the starter solenoid contains the voltage supplied by the battery. In addition, the conductor is typically sized to carry a significant amount of current needed to drive the starter.
[0003] In a typical motor vehicle 12 volt electrical system, the current that goes through the starter circuit has an initial surge of 900 to 1500 amps and has a steady state current of 200 to 600 amps for about six seconds. Of all the electrical cables in a motor vehicle, the starter cable can provide the most energy at a short. It is impractical to protect the starter circuit with a fuse since a large fuse would be required to support the current needed to power the starter. This size fuse would provide little or no protection during the periods of time when current is not needed to operate the starter. As a result, in certain conditions, such as when the starter circuit wire insulation is cut or pierced, an unprotected starter circuit could cause electrical arcing or short circuits. This could shut down the vehicle or damage other components.
[0004] Some existing battery protection devices are capable of shutting off power to the entire electrical system under certain conditions. Such conditions include detection of a short circuit condition, battery low voltage, or activation of a theft deterrent system. Likewise, short circuit current sensors can be used in a system to shut off current after a short condition occurs. However, these devices shut off current only after the short has already occurred.
[0005] As the need for energy in motor vehicles increases with the introduction of more electrically powered components and systems, vehicle manufacturers are contemplating the introduction of higher voltage electrical architectures. Current proposals contemplate replacing 12 volt systems with a 42 volt system. The use of higher voltages increases the probability that a damaged starter cable could result in an electrical arc. The use of higher voltages also increases the amount of energy available to damage vehicle components and systems. Therefore, use of higher voltage vehicle electrical systems will need short circuit protection for the battery source.
[0006] Thus far, the prior art does not adequately address preventing short circuits and electrical arcing from occurring in a starter circuit.
SUMMARY OF THE INVENTION
[0007] The present invention overcomes the problems noted above and satisfies a need for a short circuit protection system for an electrical circuit that connects a battery to an unfused device. The invention overcomes the problems of the prior art by providing a system that removes voltage from the circuit that electrically connects a device to a DC power source, such as a battery, during periods when the device does not require power.
[0008] The present invention is particularly useful to protect a starter circuit from short circuits, electrical arcing, and current leakage. In contrast to battery disconnect systems known in the prior art, this invention can remove energy from a single circuit without shutting down power to the entire electrical system. The present invention can thus be incorporated with battery protection systems and anti-theft systems known in the prior art. When used as a motor vehicle starter circuit protection system, the present invention protects the circuit while the vehicle is in operation. Other vehicle battery disconnect systems disconnect power only when conditions such as low battery voltage are detected.
[0009] In accordance with the present invention, a short circuit protection system is provided to electrically protect a section of conductor that is a part of the conductive path between a DC power source, such as a battery, and a device powered by the DC power source. The system comprises two switches in the conductive path between the battery and the device. It also includes a microprocessor capable of receiving inputs indicating that the device is to be turned on and shut off and further capable of generating ouputs to open and close the two switches.
[0010] In accordance with the present invention, a method is provided to remove voltage from a section of electrical conductor that is a part of the conductive path between a DC power source, such as a battery, and a device powered by the DC power source. A preferred method comprises the steps of detecting a signal indicating the device is to be shut off, opening a switch that lies in the conductive path between the device and a first end of the section of conductor to be protected, and then opening a second switch that lies in the conductive path between the battery and the other end of the section of conductor to be protected. An advantage of using this method is that the switch located between the battery and the section of conductor to be protected closes when there is no electrical load. As a result, this switch can be designed to be less rigorous than the switch located between the device and the section of conductor to be protected.
[0011] In accordance with another preferred aspect of the present invention, the method includes the steps of detecting a signal indicating the device is to be turned on, closing the switch that lies in the conductive path between the battery and a first end of the section of conductor to be protected, and then closing a second switch that lies in the conductive path between the device and the second end of the section of conductor to be protected. Once these steps are completed, power is provided to the device. The method further comprises the steps of detecting a signal indicating the device is to be shut off, opening the second switch that lies in the conductive path between the device and second end of the section of conductor to be protected, and then opening the switch that lies in the conductive path between the battery and the first end of the section of conductor to be protected. As a result, power is first removed from the device then removed from the section of conductor to be protected. An advantage of using this method is that the switch located between the battery and the first end of the section of conductor to be protected always closes and opens when there is no electrical load. As a result, this switch can be designed to be less rigorous than the switch located between the device and the section of conductor to be protected.
[0012] It is thus an object of the present invention to provide an improved system that removes voltage from a section of the circuit that electrically connects a battery to a device powered by the battery;
[0013] It is yet another object of the present invention to enable the use of a switch in the conductive path that is less rigorous than a second switch located in the conductive path.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The invention may take physical form in certain parts and arrangement of parts, the preferred embodiment of which will be described in detail and illustrated in the accompanying drawings which form a part hereof and wherein:
[0015] [0015]FIG. 1 is a circuit diagram illustrating the present invention; and
[0016] [0016]FIG. 2 is a flow diagram of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Referring now to the drawings, FIG. 1 is a circuit diagram of a short circuit protection system 10 utilized to protect an unfused starter circuit, such as a motor vehicle starter circuit. A positive terminal 12 of a battery 14 is electrically connected to a device, in this case a starter, 16 via a conductive path that includes a starter circuit 18 . The positive terminal 12 of the battery 14 is also electrically connected to other vehicle electrical loads such as lights 20 a , radio 20 b , and generator 20 c . It will be appreciated that other vehicle loads may be added such as air conditioning, etc. A starter switch 22 is located within the starter circuit 18 . The starter switch 22 is an preferably an electromechanical switch actuated by a relay (starter solenoid relay) 34 . Another switch, a battery disconnect device (BDD) switch 24 , is located within the starter circuit 18 between the starter switch 22 and the battery 14 . The BDD switch 24 is preferably an electromechanical switch actuated by a relay (BDD relay) 32 . A protected conductor 26 completes the circuit 18 and runs between battery 14 and starter 16 , with switches 22 and 24 there between. The protected conductor 26 represents a portion of the starter circuit 18 that is electrically protected by the present invention. The protected conductor 26 has a first end 28 that connects to the BDD switch 24 and a second end 30 that connects to the starter switch 22 .
[0018] As to switches 22 and 24 , it will be appreciated that other types of switches such as solid state switches may also be used. It will also be appreciated that the switches may be actuated by other mechanisms such as solid state devices.
[0019] The starter switch 22 and the BDD switch 24 are normally open and no power is supplied to the starter 16 . Power is provided to starter 16 when starter switch 22 and BDD switch 24 are closed. A microprocessor (BDD controller) 36 provides the logic necessary to open BDD switch 24 via a BDD switch output 38 . The BDD controller 36 also provides the logic necessary to open and close the starter switch 22 via a starter switch output 40 . It will be appreciated that the logic necessary to open and close the BDD switch 24 and the starter switch 22 can be transmitted directly from another controller such as an engine control module 42 .
[0020] In the preferred embodiment, the BDD controller 36 receives input of an ignition switch 44 activation from the engine control module 42 via an input 46 . It will be appreciated that the ignition switch 44 activation signal can be transmitted directly from the ignition switch 44 to the BDD controller 36 . It will also be appreciated that the ignition switch 44 activation signal can originate from the ignition switch within the vehicle or from another device such as a remote starter (not shown). The engine control module is also capable of providing other input signals to the BDD controller. Examples of such input signals include indications of an electrical system short circuit and vehicle theft deterrent system activation. The BDD controller 36 can also use signals of this type to command the BDD switch 24 and/or the starter switch 22 to open or close.
[0021] The BDD controller 36 controls the starter switch 22 by providing a command signal via a starter switch output 40 to an underhood bussed electrical center (UH-BEC) starter relay 48 that actuates a UH-BEC switch 50 . The UH-BEC switch 50 is located in a solenoid circuit 52 intermediate to the positive terminal 12 of the battery 14 and the starter solenoid relay 34 . When the UH-BEC switch 50 closes, power is supplied to enable the starter solenoid relay 34 to close the starter switch 22 . When the UH-BEC switch 50 opens, power is no longer supplied to the starter solenoid relay 34 . This causes the starter solenoid relay 34 to open the starter switch 22 . This approach is used to actuate the starter solenoid relay 34 because the signal output provided by a typical microprocessor does not have sufficient current to directly actuate a solenoid relay such as that found in the preferred embodiment.
[0022] When the starter switch 22 and the BDD switch 24 are both closed the battery 14 supplies power to the starter 16 that then operates to start an internal combustion engine (not shown). When the starter switch 22 is open and the BDD switch 24 is closed power is not supplied to the starter 16 , but voltage is still present in the protected conductor 26 . When the BDD switch 24 is open, voltage is removed from the protected conductor 26 and the starter 16 .
[0023] Referring now to FIG. 2, a flowchart 110 illustrates a preferred embodiment of a method to close and open the circuit connecting the starter to a DC power source such as a battery. It will be appreciated that this method can be used to add and remove voltage from a circuit connecting a DC power supply to other types of devices.
[0024] A first step 112 depicts a vehicle driver actuating a vehicle ignition switch. A remote switch or some other mechanism may also be used to initiate vehicle start-up. A step 114 indicates that the vehicle engine control module receives a command signal indicating ignition switch activation and also further transmits a command signal indicating ignition switch activation. The command signal typically originates from the ignition switch or a remote starter. The function of retransmitting the signal may be omitted if all processing is performed in the same processor. The BDD controller then receives a signal indicating a command to start the vehicle 116 . In step 118 the BDD controller generates a command signal to close the BDD switch. Alternatively the engine control module or another controller can generate the signal. It should be noted that the BDD controller could be configured so that no signal is generated when a short circuit condition or a vehicle theft is detected. Step 120 indicates that the BDD switch closes. The BDD switch is located in the starter circuit between a first end of the protected conductor and the battery. In step 122 the BDD controller generates a signal to close the UH-BEC switch or the starter switch if there is no UH-BEC switch. Alternatively the engine control module or another controller can generate the signal. Step 124 indicates to close the UH-BEC switch. This step is by-passed if there is no starter relay. Step 126 indicates to close the starter switch. The starter switch is located in the starter circuit between a second end of the protected cable and the starter. At this point the starter is powered and cranks the ignition.
[0025] Step 128 indicates the driver ceases to actuate the vehicle ignition switch or equivalent. Step 130 indicates that the vehicle engine control module receives a command signal indicating ignition switch activation has ceased and also further transmits a command signal indicating ignition switch activation has ceased. The command signal typically originates from the ignition switch or a remote starter. Another controller may also perform this step. The step is bypassed if the BDD controller performs the function. Step 132 indicates the BDD controller receives a signal indicating the ignition switch is no longer actuated. This step is by-passed if the ECM transmits the signals directly to the relays. In step 134 the BDD controller generates a signal to open the UH-BEC switch or to open the starter switch if there is no UH-BEC switch. Alternatively, the engine control module or another controller generates the signal. Step 136 indicates the UH-BEC switch opens. This step is by-passed if there is no UH-BEC switch. Step 138 indicates the starter switch opens. When this step is complete, power is no longer supplied to the starter and it ceases to operate. In step 140 the BDD controller generates a command signal to open the BDD switch. Alternatively, the engine control module or another controller may generate the signal. Step 142 indicates to open the BDD switch. After this occurs, voltage is removed from the protected conductor. The sequence begins again at step 112 the next time the vehicle driver actuates the ignition switch.
[0026] This invention has been described with reference to the preferred embodiment and modifications thereto. Further modifications and alterations may occur to others upon reading and understanding the specification. It is intended to include all such modifications and alterations insofar as they come within the scope of the invention. For example, one skilled in the art would realize that where signal generating, sending, or receiving is described herein, the intended purpose can also be accomplished by modifying or terminating an existing signal.
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A method and apparatus are provided for short circuit protection to a motor vehicle starter circuit. The invention includes providing a switching mechanism positioned intermediate to a DC power source and the starter. A controller manipulates the switching mechanism between an open position and a closed position, the closed position connecting the starter circuit to the DC power source and the open position disconnecting the starter circuit from the DC power source.
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FIELD OF THE INVENTION
[0001] The present application relates to cleaning and/or treatment compositions comprising anti-foams and methods of making and using such compositions.
BACKGROUND OF THE INVENTION
[0002] Cleaning and/or treatment compositions may employ materials that produce suds. In certain cleaning and/or treatment compositions, the level of suds is higher than desired. One manner of reducing suds is to add an antifoamer to the cleaning and/or treatment composition. Unfortunately, antifoamers may be incompatible with other compositional components or the situs that is treated thus leading to product instability. The compositions disclosed herein address in part, certain aspects of such stability issue.
SUMMARY OF THE INVENTION
[0003] The present application relates to cleaning and/or treatment compositions comprising anti-foams and methods of making and using such compositions. Such compositions encompass consumer products, cleaning and/or treatment compositions, fabric care compositions, or liquid laundry detergents that provide the desired suds profile via the addition of an antifoamer, yet are stable.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0004] As used herein “consumer product” means baby care, beauty care, fabric & home care, family care, feminine care, health care, snack and/or beverage products or devices intended to be used or consumed in the form in which it is sold, and not intended for subsequent commercial manufacture or modification. Such products include but are not limited to diapers, bibs, wipes; products for and/or methods relating to treating hair (human, dog, and/or cat), including, bleaching, coloring, dyeing, conditioning, shampooing, styling; deodorants and antiperspirants; personal cleansing; cosmetics; skin care including application of creams, lotions, and other topically applied products for consumer use; and shaving products, products for and/or methods relating to treating fabrics, hard surfaces and any other surfaces in the area of fabric and home care, including: air care, car care, dishwashing, fabric conditioning (including softening), laundry detergency, laundry and rinse additive and/or care, hard surface cleaning and/or treatment, and other cleaning for consumer or institutional use; products and/or methods relating to bath tissue, facial tissue, paper handkerchiefs, and/or paper towels; products and/or methods relating to oral care including toothpastes, tooth gels, tooth rinses, denture adhesives, tooth whitening; over-the-counter health care including pain relievers, pet health and nutrition, and water purification.
[0005] As used herein, the term “cleaning and/or treatment composition” includes, unless otherwise indicated, granular or powder-form all-purpose or “heavy-duty” washing agents, especially cleaning detergents; liquid, gel or paste-form all-purpose washing agents, especially the so-called heavy-duty liquid types; liquid fine-fabric detergents; hand dishwashing agents or light duty dishwashing agents, especially those of the high-foaming type; machine dishwashing agents, including the various tablet, granular, liquid and rinse-aid types for household and institutional use; liquid cleaning and disinfecting agents, including antibacterial hand-wash types, cleaning bars, mouthwashes, denture cleaners, dentifrice, car or carpet shampoos, bathroom cleaners; hair shampoos and hair-rinses; shower gels and foam baths and metal cleaners; as well as cleaning auxiliaries such as bleach additives and “stain-stick” or pre-treat types, substrate-laden products such as dryer added sheets, dry and wetted wipes and pads, nonwoven substrates, and sponges; as well as sprays and mists.
[0006] As used herein, the term “fabric care composition” includes, unless otherwise indicated, fabric softening compositions, fabric enhancing compositions, fabric freshening compositions and combinations thereof.
[0007] As used herein, the articles “a” and “an” when used in a claim, are understood to mean one or more of what is claimed or described.
[0008] As used herein, the terms “include”, “includes” and “including” are meant to be synonymous with the phrase “including but not limited to”.
[0009] As used herein, the term “solid” means granular, powder, bar and tablet product forms. As used herein, the term “situs” includes paper products, fabrics, garments, hard surfaces, hair and skin.
[0010] As used herein, the term “heteroatom” takes its ordinary, customary meaning, and thus includes N, O, S, P, Cl, Br, and I.
[0011] Unless otherwise noted, all component or composition levels are in reference to the active portion of that component or composition, and are exclusive of impurities, for example, residual solvents or by-products, which may be present in commercially available sources of such components or compositions.
[0012] All percentages and ratios are calculated by weight unless otherwise indicated. All percentages and ratios are calculated based on the total composition unless otherwise indicated.
[0013] It should be understood that every maximum numerical limitation given throughout this specification includes every lower numerical limitation, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this specification will include every higher numerical limitation, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this specification will include every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.
Compositions
[0014] In one aspect, a composition comprising a polymer, having a number average molecular weight of from about 200 Daltons to about 10,000,000 Daltons, from about 500 Daltons to about 10,000,000 Daltons, from about 1,000 Daltons to about 10,000,000 Daltons, or from about 1,500 Daltons to about 10,000,000 Daltons, that comprises from about 50 mol % to about 100 mol %, or from about 60 mol % to about 100 mol %, or from about 70 mol % to about 100 mol %, or from about 80 mol % to about 100 mol %, or from about 90 mol % to about 100 mol % units of Formula (I) below,
[0000] R a (R 1 O) b R 2 c SiO (4-a-b-c)/2 Formula (I)
wherein: a) each R is independently selected from: H, a monovalent, SiC-bonded, optionally substituted, aliphatic hydrocarbon radical that optionally comprises a heteroatom, or an aromatic hydrocarbon radical covalently attached to silicon via aliphatic groups, in one aspect each R is independently selected from: H, a monovalent, SiC-bonded, optionally substituted, C 1 -C 50 aliphatic hydrocarbon radical that optionally comprises a heteroatom, or a C 6 -C 16 aromatic hydrocarbon radical covalently attached to silicon via aliphatic groups; b) each R 1 is independently selected from: H, or a monovalent, optionally substituted aliphatic hydrocarbon radical, that optionally comprises a heteroatom, in one aspect each R 1 is independently selected from: H, or a monovalent, optionally substituted C 1 -C 50 aliphatic hydrocarbon radical, that optionally comprises a heteroatom; c) each R 2 is a monovalent, optionally substituted, aromatic hydrocarbon radical which is attached to the silicon atom via a carbon ring atom, in one aspect each R 2 is a monovalent, optionally substituted, C 6 -C 16 aromatic hydrocarbon radical which is attached to the silicon atom via a carbon ring atom; d) the index a is 0, 1, 2 or 3; e) the index b is 0, 1, 2 or 3; f) the index c is 0, 1, 2 or 3; and optionally a filler and a resin; with the proviso for said polymer that for each of said polymer's Formula I units the sum of indices a, b, and c is less than or equal to 3; in 1-100%, 10-60%, or 20-40% of said polymer's Formula (I) units, c is other than 0; and in at least 50% of said polymer's Formula I units the sum of indices a, b, and c is 2.
[0024] In one aspect, said polymer's number average molecular weight is from about 200 Daltons to about 10,000,000 Daltons, from about 500 Daltons to about 1,000,000 Daltons, from about 1,000 Daltons to about 500,000 Daltons, or from about 1,500 Daltons to about 100,000 Daltons.
[0025] In one aspect of said composition, for:
a) each R group of said polymer:
i) each monovalent, optionally substituted, aliphatic hydrocarbon radical that optionally comprises a heteroatom is independently selected from methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, tert-butyl, n-pentyl, isopentyl, neopentyl, tert-pentyl, hexyl, heptyl, octyl, isooctyl, nonyl, decyl, dodecyl, alkenyl, cycloalkyl, 3,3,3-trifluoro-n-propyl, cyanoethyl, glycidyloxy-n-propyl, polyalkylene glycol-n-propyl, amino-n-propyl, aminoethylamino-n-propyl, and methacryloyloxy-n-propyl, ii) each aromatic hydrocarbon radical covalently attached to silicon via aliphatic groups is independently selected from benzyl, phenylethyl, or 2-phenylpropyl,
b) each R 1 group of said polymer each monovalent, optionally substituted, aliphatic hydrocarbon radical that optionally comprises a heteroatom is independently selected from methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, tert-butyl, n-pentyl, isopentyl, neopentyl, tert-pentyl, hexyl, heptyl, octyl, isooctyl, nonyl, decyl, dodecyl, alkenyl, cycloalkyl, 3,3,3-trifluoro-n-propyl, cyanoethyl, glycidyloxy-n-propyl, polyalkylene glycol-n-propyl, amino-n-propyl, aminoethylamino-n-propyl, and methacryloyloxy-n-propyl, c) each R 2 group of said polymer is independently selected from phenyl, substituted phenyl, naphthyl, or anthracyl.
[0031] In one aspect of said composition, for each R 2 group of said polymer is independently selected from phenyl, toloyl, xylyl, cumyl, naphthyl or anthracyl.
[0032] In one aspect of said composition, for each R 2 group of said polymer is independently selected from phenyl or toloyl.
[0033] In one aspect of said composition, the index b is 0 or 1, and the index c is 0, 1, or 2.
[0034] In one aspect of said composition, said composition comprises a resin and a filler, said filler having a BET surface area of 20 to 1000 m 2 /g, a particle size of less than 10 μm and an agglomerate size of less than 100 μm.
[0035] In one aspect of said composition, said filler is selected from the group consisting of silica, titanium dioxide, aluminum oxide, metal soaps, quartz flour, PTFE powders, fatty acid amides, ethylenebisstearamide, or hydrophobic polyurethanes.
[0036] In one aspect of said composition said filler comprises hydrophobic, precipitated silica and/or hydrophobic, fumed silica.
[0037] In one aspect of said composition, viscosity, at a shear rate of 20 sec at 25° C., of from about 10 cPs to about 50,000 cPs and comprising from about 1% to about 60%, from about 3% to about 50%, from about 5% to about 40% or from about 8% to about 30% of a surfactant selected from the group consisting of anionic surfactant, cationic surfactant, nonionic surfactant, zwitterionic surfactant, ampholytic surfactant and mixtures thereof and optionally one or more adjuncts are selected from the group consisting of builders, chelating agents, dye transfer inhibiting agents, dispersants, enzymes, and enzyme stabilizers, catalytic materials, bleach, bleach activators, polymeric dispersing agents, clay soil removal/anti-redeposition agents, brighteners, suds suppressors, dyes, hueing agents, UV absorbers, perfume, perfume delivery systems, structure elasticizing agents, thickeners/structurants, fabric softeners, carriers, hydrotropes, processing aids and/or pigments.
[0038] In one aspect of said composition, said composition comprises an anionic surfactant.
[0039] In one aspect of said composition, said anionic surfactant is selected from the group consisting of a C 11 -C 18 alkyl benzene sulfonate surfactant; a C 10 -C 20 alkyl sulfate surfactant; a C 10 -C 18 alkyl alkoxy sulfate surfactant, said C 10 -C 18 alkyl alkoxy sulfate surfactant having an average degree of alkoxylation of from 1 to 30 and the alkoxy comprises a C 1 -C 4 chain, and mixtures thereof.
[0040] In one aspect of said composition, said one or more adjuncts are selected from the group consisting of builders, chelating agents, dye transfer inhibiting agents, dispersants, enzymes, and enzyme stabilizers, catalytic materials, bleach, bleach activators, polymeric dispersing agents, clay soil removal/anti-redeposition agents, brighteners, suds suppressors, dyes, hueing agents, UV absorbers, perfume, perfume delivery systems, structure elasticizing agents, thickeners/structurants, fabric softeners, carriers, hydrotropes, processing aids and/or pigments.
[0041] In one aspect of said composition, said composition is a antifoam composition that comprises a filler and a resin and said resin comprising units of Formula (II) below:
[0000] R 3 d (R 4 O) e SiO (4-d-e)/2 Formula (II)
wherein:
a) each R 3 is independently selected from H, a monovalent, SiC-bonded, optionally substituted, aliphatic hydrocarbon radical that optionally comprises a heteroatom, or an aromatic hydrocarbon radical covalently attached to silicon via aliphatic groups, in one aspect, each R 3 is independently selected from H, a monovalent, SiC-bonded, optionally substituted, C 1 -C 50 aliphatic hydrocarbon radical that optionally comprises a heteroatom, or a C 6 -C 16 aromatic hydrocarbon radical covalently attached to silicon via aliphatic groups; b) each R 4 is independently selected from H, or a monovalent, optionally substituted aliphatic hydrocarbon radical, that optionally comprises a heteroatom, in one aspect, each R 4 is independently selected from H, or a monovalent, optionally substituted C 1 -C 50 aliphatic hydrocarbon radical, that optionally comprises a heteroatom; c) the index d is 0, 1, 2 or 3; and d) the index e is 0, 1, 2 or 3;
with the proviso that the sum of the indices d and e is less than or equal to 3 and in less than 50% of all of the units of the Formula (II) in the organopolysiloxane resin the sum of the indices d and e is 2.
[0048] In one aspect, said composition is a consumer product.
[0049] In one aspect, said composition is a cleaning and/or treatment composition.
[0050] In one aspect, said composition is a fabric care composition.
[0051] In one aspect, said composition is a liquid laundry detergent.
[0052] In one aspect, a composition comprising any combinations of the parameters and/or characteristics disclosed above is disclosed.
Process of Making Compositions
[0053] In one aspect, a process of making the composition disclosed herein is disclosed, said process comprising combining a surfactant, optionally one or more adjunct ingredients, and from about 0.001% to about 2%, or from about 0.005% to about 1%, or from about 0.01% to about 0.75%, or from about 0.05% to about 0.5% of an anti-foam composition disclosed herein comprising a polymer having a number average molecular weight of from about 200 Daltons to about 10,000,000 Daltons, from about 500 Daltons to about 10,000,000 Daltons, from about 1,000 Daltons to about 10,000,000 Daltons, or from about 1,500 Daltons to about 10,000,000 Daltons, that comprises from about 50 mol % to about 100 mol %, or from about 60 mol % to about 100 mol %, or from about 70 mol % to about 100 mol %, or from about 80 mol % to about 100 mol %, or from about 90 mol % to about 100 mol % units of Formula (I) below,
[0000] R a (R 1 O) b R 2 c SiO (4-a-b-c)/2 Formula (I)
wherein:
a) each R is independently selected from: H, a monovalent, SiC-bonded, optionally substituted, aliphatic hydrocarbon radical that optionally comprises a heteroatom, or an aromatic hydrocarbon radical covalently attached to silicon via aliphatic groups, in one aspect, each R is independently selected from: H, a monovalent, SiC-bonded, optionally substituted, C 1 -C 50 aliphatic hydrocarbon radical that optionally comprises a heteroatom, or a C 6 -C 16 aromatic hydrocarbon radical covalently attached to silicon via aliphatic groups; b) each R 1 is independently selected from: H, or a monovalent, optionally substituted aliphatic hydrocarbon radical, that optionally comprises a heteroatom, in one aspect, each R 1 is independently selected from: H, or a monovalent, optionally substituted C 1 -C 50 aliphatic hydrocarbon radical, that optionally comprises a heteroatom; c) each R 2 is a monovalent, optionally substituted, aromatic hydrocarbon radical which is attached to the silicon atom via a carbon ring atom, in one aspect, each R 2 is a monovalent, optionally substituted, C 6 -C 16 aromatic hydrocarbon radical which is attached to the silicon atom via a carbon ring atom; d) the index a is 0, 1, 2 or 3; e) the index b is 0, 1, 2 or 3; f) the index c is 0, 1, 2 or 3; and
optionally a filler and a resin; with the proviso for said polymer that for each of said polymer's Formula I units the sum of the indices a, b, and c is less than or equal to 3; in 1-100%, 10-60%, or 20-40% of said polymer's Formula I units, c is other than 0; and in at least 50% of said polymer's Formula I units the sum of the indices a, b, and c is 2.
[0062] In one aspect, said process, said polymer's number average molecular weight is from about 200 Daltons to about 10,000,000 Daltons, from about 500 Daltons to about 1,000,000 Daltons, from about 1,000 Daltons to about 500,000 Daltons, or from about 1,500 Daltons to about 100,000 Daltons.
Method of Using of Compositions
[0063] In one aspect, a method of treating and/or cleaning a situs is disclosed, said method comprising:
[0064] a) optionally washing and/or rinsing said situs;
[0065] b) contacting said situs with any of Applicants' compositions, and
[0066] c) optionally washing and/or rinsing said situs.
[0067] In one aspect, said situs is dried either line dried and/or machine dried after said treating and/or cleaning.
Adjunct Materials
[0068] While not essential for each consumer product embodiment of the present invention, the non-limiting list of adjuncts illustrated hereinafter are suitable for use in the instant consumer products and may be desirably incorporated in certain embodiments of the invention, for example to assist or enhance performance, for treatment of the substrate to be cleaned, or to modify the aesthetics of the composition as is the case with perfumes, colorants, dyes or the like. The precise nature of these additional components, and levels of incorporation thereof, will depend on the physical form of the composition and the nature of the operation for which it is to be used. Suitable adjunct materials include, but are not limited to, solvents, builders, chelating agents, dye transfer inhibiting agents, dispersants, enzymes, and enzyme stabilizers, catalytic materials, bleach activators, polymeric dispersing agents, clay soil removal/anti-redeposition agents, brighteners, suds suppressors, dyes, UV absorbers, additional perfume and perfume delivery systems, structure elasticizing agents, thickeners/structurants, fabric softeners, carriers, hydrotropes, processing aids and/or pigments. In addition to the disclosure below, suitable examples of such other adjuncts and levels of use are found in U.S. Pat. Nos. 5,576,282, 6,306,812 B1 and 6,326,348 B1 that are incorporated by reference.
[0069] As stated, the adjunct ingredients are not essential for each consumer product embodiment of the present invention. Thus, certain embodiments of Applicants' compositions do not contain one or more of the following adjuncts materials: bleach activators, solvents, builders, chelating agents, dye transfer inhibiting agents, dispersants, enzymes, and enzyme stabilizers, catalytic metal complexes, polymeric dispersing agents, clay and soil removal/anti-redeposition agents, brighteners, suds suppressors, dyes, additional perfumes and perfume delivery systems, structure elasticizing agents, thickeners/structurants, fabric softeners, carriers, hydrotropes, processing aids and/or pigments. However, when one or more adjuncts is present, such one or more adjuncts may be present as detailed below.
[0070] Solvents—suitable solvents include, but are not limited to, water, alcohol, paraffins, glycols, glycerols, and mixtures thereof.
[0071] Builders—The compositions of the present invention can comprise one or more detergent builders or builder systems. When present, the compositions will typically comprise at least about 1% builder, or from about 5% or 10% to about 80%, 50%, or even 30% by weight, of said builder. Builders include, but are not limited to, the alkali metal, ammonium and alkanolammonium salts of polyphosphates, alkali metal silicates, alkaline earth and alkali metal carbonates, aluminosilicate builders, polycarboxylate compounds, ether hydroxypolycarboxylates, copolymers of maleic anhydride with ethylene or vinyl methyl ether, 1,3,5-trihydroxybenzene-2,4,6-trisulphonic acid, and carboxymethyl-oxysuccinic acid, the various alkali metal, ammonium and substituted ammonium salts of polyacetic acids such as ethylenediamine tetraacetic acid and nitrilotriacetic acid, as well as polycarboxylates such as mellitic acid, succinic acid, oxydisuccinic acid, polymaleic acid, benzene 1,3,5-tricarboxylic acid, carboxymethyloxysuccinic acid, and soluble salts thereof.
[0072] Chelating Agents—The compositions herein may also optionally contain one or more copper, iron and/or manganese chelating agents. If utilized, chelating agents will generally comprise from about 0.1% by weight of the compositions herein to about 15%, or even from about 3.0% to about 15% by weight of the compositions herein.
[0073] Dye Transfer Inhibiting Agents—The compositions of the present invention may also include one or more dye transfer inhibiting agents. Suitable polymeric dye transfer inhibiting agents include, but are not limited to, polyvinylpyrrolidone polymers, polyamine N-oxide polymers, copolymers of N-vinylpyrrolidone and N-vinylimidazole, polyvinyloxazolidones and polyvinylimidazoles or mixtures thereof. When present in the compositions herein, the dye transfer inhibiting agents are present at levels from about 0.0001%, from about 0.01%, from about 0.05% by weight of the cleaning compositions to about 10%, about 2%, or even about 1% by weight of the cleaning compositions.
[0074] Dispersants—The compositions of the present invention can also contain dispersants. Suitable water-soluble organic materials are the homo- or co-polymeric acids or their salts, in which the polycarboxylic acid may comprise at least two carboxyl radicals separated from each other by not more than two carbon atoms.
[0075] Enzymes—The compositions can comprise one or more detergent enzymes which provide cleaning performance and/or fabric care benefits. Examples of suitable enzymes include, but are not limited to, hemicellulases, peroxidases, proteases, cellulases, xylanases, lipases, phospholipases, esterases, cutinases, pectinases, keratanases, reductases, oxidases, phenoloxidases, lipoxygenases, ligninases, pullulanases, tannases, pentosanases, malanases, β-glucanases, arabinosidases, hyaluronidase, chondroitinase, laccase, and amylases, or mixtures thereof. A typical combination is a cocktail of conventional applicable enzymes like protease, lipase, cutinase and/or cellulase in conjunction with amylase.
[0076] Enzyme Stabilizers—Enzymes for use in compositions, for example, detergents can be stabilized by various techniques. The enzymes employed herein can be stabilized by the presence of water-soluble sources of calcium and/or magnesium ions in the finished compositions that provide such ions to the enzymes.
[0077] Fabric Hueing Agents—The composition may comprise a fabric hueing agent (sometimes referred to as shading, bluing or whitening agents). Typically the hueing agent provides a blue or violet shade to fabric. Hueing agents can be used either alone or in combination to create a specific shade of hueing and/or to shade different fabric types. This may be provided for example by mixing a red and green-blue dye to yield a blue or violet shade. Hueing agents may be selected from any known chemical class of dye, including but not limited to acridine, anthraquinone (including polycyclic quinones), azine, azo (e.g., monoazo, disazo, trisazo, tetrakisazo, polyazo), including premetallized azo, benzodifurane and benzodifuranone, carotenoid, coumarin, cyanine, diazahemicyanine, diphenylmethane, formazan, hemicyanine, indigoids, methane, naphthalimides, naphthoquinone, nitro and nitroso, oxazine, phthalocyanine, pyrazoles, stilbene, styryl, triarylmethane, triphenylmethane, xanthenes and mixtures thereof. Suitable fabric hueing agents include dyes, dye-clay conjugates, and organic and inorganic pigments. Suitable dyes include small molecule dyes and polymeric dyes. Suitable small molecule dyes include small molecule dyes selected from the group consisting of dyes falling into the Colour Index (C.I.) classifications of Direct, Basic, Reactive or hydrolysed Reactive, Solvent or Disperse dyes for example that are classified as Blue, Violet, Red, Green or Black, and provide the desired shade either alone or in combination. In another aspect, suitable small molecule dyes include small molecule dyes selected from the group consisting of Colour Index (Society of Dyers and Colourists, Bradford, UK) numbers Direct Violet dyes such as 9, 35, 48, 51, 66, and 99, Direct Blue dyes such as 1, 71, 80 and 279, Acid Red dyes such as 17, 73, 52, 88 and 150, Acid Violet dyes such as 15, 17, 24, 43, 49 and 50, Acid Blue dyes such as 15, 17, 25, 29, 40, 45, 75, 80, 83, 90 and 113, Acid Black dyes such as 1, Basic Violet dyes such as 1, 3, 4, 10 and 35, Basic Blue dyes such as 3, 16, 22, 47, 66, 75 and 159, Disperse or Solvent dyes such as those described in US 2008/034511 A1 or U.S. Pat. No. 8,268,016 B2, or dyes as disclosed in U.S. Pat. No. 7,208,459 B2, and mixtures thereof. In another aspect, suitable small molecule dyes include small molecule dyes selected from the group consisting of C. I. numbers Acid Violet 17, Direct Blue 71, Direct Violet 51, Direct Blue 1, Acid Red 88, Acid Red 150, Acid Blue 29, Acid Blue 113 or mixtures thereof.
[0078] Suitable polymeric dyes include polymeric dyes selected from the group consisting of polymers containing covalently bound (sometimes referred to as conjugated) chromogens, (dye-polymer conjugates), for example polymers with chromogens co-polymerized into the backbone of the polymer and mixtures thereof. Polymeric dyes include those described in WO2011/98355, US 2012/225803 A1, US 2012/090102 A1, U.S. Pat. No. 7,686,892 B2, and WO2010/142503.
[0079] In another aspect, suitable polymeric dyes include polymeric dyes selected from the group consisting of fabric-substantive colorants sold under the name of Liquitint® (Milliken, Spartanburg, S.C., USA), dye-polymer conjugates formed from at least one reactive dye and a polymer selected from the group consisting of polymers comprising a moiety selected from the group consisting of a hydroxyl moiety, a primary amine moiety, a secondary amine moiety, a thiol moiety and mixtures thereof. In still another aspect, suitable polymeric dyes include polymeric dyes selected from the group consisting of Liquitint® Violet CT, carboxymethyl cellulose (CMC) covalently bound to a reactive blue, reactive violet or reactive red dye such as CMC conjugated with C.I. Reactive Blue 19, sold by Megazyme, Wicklow, Ireland under the product name AZO-CM-CELLULOSE, product code S-ACMC, alkoxylated triphenyl-methane polymeric colourants, alkoxylated thiophene polymeric colourants, and mixtures thereof.
[0080] Preferred hueing dyes include the whitening agents found in WO 08/87497 A1, WO2011/011799 and US 2012/129752 A1. Preferred hueing agents for use in the present invention may be the preferred dyes disclosed in these references, including those selected from Examples 1-42 in Table 5 of WO2011/011799. Other preferred dyes are disclosed in U.S. Pat. No. 8,138,222. Other preferred dyes are disclosed in U.S. Pat. No. 7,909,890 B2.
[0081] Suitable dye clay conjugates include dye clay conjugates selected from the group comprising at least one cationic/basic dye and a smectite clay, and mixtures thereof. In another aspect, suitable dye clay conjugates include dye clay conjugates selected from the group consisting of one cationic/basic dye selected from the group consisting of C.I. Basic Yellow 1 through 108, C.I. Basic Orange 1 through 69, C.I. Basic Red 1 through 118, C.I. Basic Violet 1 through 51, C.I. Basic Blue 1 through 164, C.I. Basic Green 1 through 14, C.I. Basic Brown 1 through 23, CI Basic Black 1 through 11, and a clay selected from the group consisting of Montmorillonite clay, Hectorite clay, Saponite clay and mixtures thereof. In still another aspect, suitable dye clay conjugates include dye clay conjugates selected from the group consisting of: Montmorillonite Basic Blue B7 C.I. 42595 conjugate, Montmorillonite Basic Blue B9 C.I. 52015 conjugate, Montmorillonite Basic Violet V3 C.I. 42555 conjugate, Montmorillonite Basic Green G1 C.I. 42040 conjugate, Montmorillonite Basic Red R1 C.I. 45160 conjugate, Montmorillonite C.I. Basic Black 2 conjugate, Hectorite Basic Blue B7 C.I. 42595 conjugate, Hectorite Basic Blue B9 C.I. 52015 conjugate, Hectorite Basic Violet V3 C.I. 42555 conjugate, Hectorite Basic Green G1 C.I. 42040 conjugate, Hectorite Basic Red R1 C.I. 45160 conjugate, Hectorite C.I. Basic Black 2 conjugate, Saponite Basic Blue B7 C.I. 42595 conjugate, Saponite Basic Blue B9 C.I. 52015 conjugate, Saponite Basic Violet V3 C.I. 42555 conjugate, Saponite Basic Green G1 C.I. 42040 conjugate, Saponite Basic Red R1 C.I. 45160 conjugate, Saponite C.I. Basic Black 2 conjugate and mixtures thereof.
[0082] Suitable pigments include pigments selected from the group consisting of flavanthrone, indanthrone, chlorinated indanthrone containing from 1 to 4 chlorine atoms, pyranthrone, dichloropyranthrone, monobromodichloropyranthrone, dibromodichloropyranthrone, tetrabromopyranthrone, perylene-3,4,9,10-tetracarboxylic acid diimide, wherein the imide groups may be unsubstituted or substituted by C1-C3-alkyl or a phenyl or heterocyclic radical, and wherein the phenyl and heterocyclic radicals may additionally carry substituents which do not confer solubility in water, anthrapyrimidinecarboxylic acid amides, violanthrone, isoviolanthrone, dioxazine pigments, copper phthalocyanine which may contain up to 2 chlorine atoms per molecule, polychloro-copper phthalocyanine or polybromochloro-copper phthalocyanine containing up to 14 bromine atoms per molecule and mixtures thereof.
[0083] In another aspect, suitable pigments include pigments selected from the group consisting of Ultramarine Blue (C.I. Pigment Blue 29), Ultramarine Violet (C.I. Pigment Violet 15) and mixtures thereof.
[0084] The aforementioned fabric hueing agents can be used in combination (any mixture of fabric hueing agents can be used).
[0085] Catalytic Metal Complexes—Applicants' compositions may include catalytic metal complexes. One type of metal-containing bleach catalyst is a catalyst system comprising a transition metal cation of defined bleach catalytic activity, such as copper, iron, titanium, ruthenium, tungsten, molybdenum, or manganese cations, an auxiliary metal cation having little or no bleach catalytic activity, such as zinc or aluminum cations, and a sequestrate having defined stability constants for the catalytic and auxiliary metal cations, particularly ethylenediaminetetraacetic acid, ethylenediaminetetra (methyl-enephosphonic acid) and water-soluble salts thereof. Such catalysts are disclosed in U.S. Pat. No. 4,430,243.
[0086] If desired, the compositions herein can be catalyzed by means of a manganese compound. Such compounds and levels of use are well known in the art and include, for example, the manganese-based catalysts disclosed in U.S. Pat. No. 5,576,282.
[0087] Cobalt bleach catalysts useful herein are known, and are described, for example, in U.S. Pat. Nos. 5,597,936 and 5,595,967. Such cobalt catalysts are readily prepared by known procedures, such as taught for example in U.S. Pat. Nos. 5,597,936, and 5,595,967.
[0088] Compositions herein may also suitably include a transition metal complex of a macropolycyclic rigid ligand—abbreviated as “MRL”. As a practical matter, and not by way of limitation, the compositions and cleaning processes herein can be adjusted to provide on the order of at least one part per hundred million of the benefit agent MRL species in the aqueous washing medium, and may provide from about 0.005 ppm to about 25 ppm, from about 0.05 ppm to about 10 ppm, or even from about 0.1 ppm to about 5 ppm, of the MRL in the wash liquor.
[0089] Preferred transition-metals in the instant transition-metal bleach catalyst include manganese, iron and chromium. Preferred MRL's herein are a special type of ultra-rigid ligand that is cross-bridged such as 5,12-diethyl-1,5,8,12-tetraazabicyclo[6.6.2]hexa-decane.
[0090] Suitable transition metal MRLs are readily prepared by known procedures, such as taught for example in WO 00/32601, and U.S. Pat. No. 6,225,464.
[0091] Suitable thickeners/structurants and useful levels of same are described in U.S. Patent Application Publication No. 2005/0130864 A1 and U.S. Pat. Nos. 7,169,741 B2 and 7,297,674 B2. In one aspect, the thickener may be a rheology modifier. The rheology modifier may be selected from the group consisting of non-polymeric crystalline, hydroxy-functional materials, polymeric rheology modifiers which impart shear thinning characteristics to the aqueous liquid matrix of the composition. In one aspect, such rheology modifiers impart to the aqueous liquid composition a high shear viscosity, at 20 sec −1 shear rate and at 21° C., of from 1 to 7,000 cps and a viscosity at low shear (0.5 sec −1 shear rate at 21° C.) of greater than 1000 cps, or even 1,000 cps to 200,000 cps. In one aspect, for cleaning and treatment compositions, such rheology modifiers impart to the aqueous liquid composition a high shear viscosity, at 20 sec −1 and at 21° C., of from 50 to 3,000 cps and a viscosity at low shear (0.5 sec −1 shear rate at 21° C.) of greater than 1,000 cps, or even 1,000 cps to 200,000 cps. Viscosity according to the present invention is measured using an AR 2000 rheometer from TA instruments using a plate steel spindle having a plate diameter of 40 mm and a gap size of 500 μm. The high shear viscosity at 20 sec −1 and low shear viscosity at 0.5 sec −1 can be obtained from a logarithmic shear rate sweep from 0.1 sec −1 to 25 sec −1 in 3 minutes time at 21° C. Crystalline hydroxyl functional materials are rheology modifiers which form thread-like structuring systems throughout the matrix of the composition upon in situ crystallization in the matrix. Polymeric rheology modifiers are selected from the group consisting of polyacrylates, polymeric gums, other non-gum polysaccharides, and combinations of these polymeric materials.
[0092] Generally, the rheology modifier will comprise from about 0.01% to about 1% by weight, from about 0.05% to about 0.75% by weight, or even from about 0.1% to about 0.5% by weight, of the compositions herein.
[0093] Structuring agents which are especially useful in the compositions of the present invention comprises non-polymeric (except for conventional alkoxylation), crystalline hydroxy-functional materials which can form thread-like structuring systems throughout the liquid matrix when they are crystallized within the matrix in situ. Such materials can be generally characterized as crystalline, hydroxyl-containing fatty acids, fatty esters or fatty waxes. In one aspect, rheology modifiers include crystalline, hydroxyl-containing rheology modifiers include castor oil and its derivatives. In one aspect, rheology modifiers may include hydrogenated castor oil derivatives such as hydrogenated castor oil and hydrogenated castor wax. Commercially available, castor oil-based, crystalline, hydroxyl-containing rheology modifiers include THIXCIN™ from Rheox, Inc. (now Elementis).
[0094] Other types of rheology modifiers, besides the non-polymeric, crystalline, hydroxyl-containing rheology modifiers described heretofore, may be utilized in the liquid detergent compositions herein. Polymeric materials which provide shear-thinning characteristics to the aqueous liquid matrix may also be employed.
[0095] Suitable polymeric rheology modifiers include those of the polyacrylate, polysaccharide or polysaccharide derivative type. Polysaccharide derivatives typically used as rheology modifiers comprise polymeric gum materials. Such gums include pectine, alginate, arabinogalactan (gum Arabic), carrageenan, gellan gum, xanthan gum and guar gum.
[0096] If polymeric rheology modifiers are employed herein, a preferred material of this type is gellan gum. Gellan gum is a heteropolysaccharide prepared by fermentation of Pseudomonaselodea ATCC 31461. Gellan gum is commercially marketed by CP Kelco U.S., Inc. under the KELCOGEL tradename.
[0097] A further alternative and suitable rheology modifier include a combination of a solvent and a polycarboxylate polymer. More specifically the solvent may be an alkylene glycol. In one aspect, the solvent may comprise dipropylene glycol. In one aspect, the polycarboxylate polymer may comprise a polyacrylate, polymethacrylate or mixtures thereof. In one aspect, solvent may be present, based on total composition weight, at a level of from 0.5% to 15%, or from 2% to 9% of the composition. In one aspect, polycarboxylate polymer may be present, based on total composition weight, at a level of from 0.1% to 10%, or from 2% to 5%. In one aspect, the solvent component may comprise mixture of dipropylene glycol and 1,2-propanediol. In one aspect, the ratio of dipropylene glycol to 1,2-propanediol may be 3:1 to 1:3, or even 1:1. In one aspect, the polyacrylate may comprise a copolymer of unsaturated mono- or di-carbonic acid and C 1 -C 30 alkyl ester of the (meth)acrylic acid. In another aspect, the rheology modifier may comprise a polyacrylate of unsaturated mono- or di-carbonic acid and C 1 -C 30 alkyl ester of the (meth)acrylic acid. Such copolymers are available from Noveon Inc under the tradename Carbopol Aqua 30®. In the absence of rheology modifier and in order to impart the desired shear thinning characteristics to the liquid composition, the liquid composition can be internally structured through surfactant phase chemistry or gel phases.
[0098] UV Absorbers—in certain consumer product embodiments of the present invention, the photo-responsive encapsulates of the present invention may be stabilized against premature release by exposure to light of a sufficient wavelength during storage by incorporation of a suitable UV-absorbing ingredients into the composition. Any suitable UV-absorbing composition may be employed, but particularly preferred are those which do not impart an unpleasant color or odor to the composition, and which do not adversely affect the rheology of the product. Non-limiting examples of UV-absorbing ingredients include avobenzone, cinoxate, ecamsule, menthyl anthranilate, octyl methoxycinnamate, octyl salicylate, oxybenzone, sulisobenzone, and combinations thereof. Other suitable UV-absorbing ingredients are disclosed in U.S. Pat. No. 6,159,918, which is incorporated herein by reference. Applicants have surprisingly found that the use of such UV-absorbing ingredients do not compromise the light-activated performance of encapsulates of the present invention. Without wishing to be bound by theory, it is believed that in many consumer product applications, e.g., cleaning compositions including laundry detergents, shampoos and body washes, the UV absorbing ingredient is washed down the drain while the encapsulates of the present invention are retained in an efficacious amount on the surface of interest where they are available to release their contents on subsequent exposure to light of a sufficient wavelength. In other cleaning compositions or leave-on consumer products, e.g., floor cleaning compositions, drapery and upholstery refreshers, body lotions, and hair styling products, it is believed that the UV-absorbing ingredients dry down to a thin film after application, allowing the encapsulates of the present invention to sit atop or extend above the film. This allows and efficacious amount of light of the desired wavelength to reach the encapsulates and effect the release of the benefit agents.
EXAMPLES
[0099] Silicone Antifoam Agent A
[0100] Silicone antifoam agent A was prepared by charging a 100 ml flask equipped with a stirrer with 22.75 g of a copolymer having a molecular weight of approximately 35,300 and comprising, 83-85 mole % dimethylsiloxane groups, 15-17 mole % diphenylsiloxane groups, terminated with a vinyl group 1 , and 6 g of an organosiloxane resin 2 having trimethyl siloxane units and SiO 2 units in a M/Q ratio of about 0.65/1 to 0.67/1 dissolved in 2-ethylhexyl stearate 3 . The mixture was stirred until complete incorporation of the resin mixture. Then 2.25 g of precipitated silica 4 and 0.75 g of fumed silica 5 was added and the mixture stirred until complete incorporation of the silica was achieved.
[0101] Silicone Antifoam Agent B
[0102] Silicone antifoam agent B was prepared by charging a 100 ml flask equipped with a stirrer with 18.2 g of a copolymer having a molecular weight of approximately 35,300 and comprising 83-85 mole % dimethylsiloxane groups, 15-17 mole % diphenylsiloxane groups, terminated with a vinyl group 1 , 4.6 g of a polydimethylsilloxane, trimethylsiloxy terminated, having a molecular weight of approximately 62,700 1 and 6 g of an organosiloxane resin 2 having trimethyl siloxane units and SiO 2 units in a M/Q ratio of about 0.65/1 to 0.67/1, dissolved in 2-ethylhexyl stearate (50% resin). The mixture was stirred until complete incorporation of the resin mixture. Then 2.25 g of precipitated silica 5 and 0.75 g of fumed silica 5 was added and the mixture stirred until complete incorporation of the silica was achieved.
[0103] Silicone Antifoam Agent C
[0104] Silicone antifoam agent C was prepared by charging a 100 ml flask equipped with a stirrer with 18.2 g of a copolymer having a viscosity of approximately 500 cSt (25° C.) and comprising 38-42 mole % dimethylsiloxane groups and 58-62 mole % phenylmethylsiloxane groups, trimethylsiloxy terminated 1 , 4.6 g of a polydimethylsiloxane, trimethylsiloxy terminated, having a molecular weight of approximately 62,700, and 6 g of an organosiloxane resin 2 having trimethyl siloxane units and SiO 2 units in a M/Q ratio of about 0.65/1 to 0.67/1 dissolved in 2-ethylhexyl stearate 3 (50% resin). The mixture was stirred until complete incorporation of the resin mixture. Then 2.25 g of precipitated silica 4 and 0.75 g of fumed silica 5 was added and the mixture stirred until complete incorporation of the silica was achieved. 1 Supplied by Gelest Inc., Morrisville, Pa. 2 Supplied by Wacker Silicones, Adrian, Mich. under the trade name Belsil 803 3 Supplied by Aldrich Chemicals, Milwaukee, Wis. 4 Available from Evonik Degussa Corporation, Parsippany, N.J. 5 Available from Evonik Degussa Corporation, Parsippany, N.J.
Formulation Example 1
Liquid Detergent Fabric Care Compositions
[0105] Liquid detergent fabric care composition 1A-1E are made by mixing together the ingredients listed in the proportions shown:
[0000]
Ingredient (wt %)
1A
1B
1C
1D
1E
C 12 -C 15 alkyl polyethoxylate
20.1
16.6
14.7
13.9
8.2
(1.8) sulfate 1
C 11.8 linear alkylbenzene
—
4.9
4.3
4.1
8.2
sulfonc acid 2
C 16 -C 17 branched alkyl
—
2.0
1.8
1.6
—
sulfate 1
C 12 alkyl trimethyl
2.0
—
—
—
ammonium chloride 4
C 12 alkyl dimethyl amine
0.7
0.6
—
—
oxide 5
C 12 -C 14 alcohol 9 ethoxylate 3
0.3
0.8
0.9
0.6
0.7
C 15 -C 16 branched alcohol -7
—
—
—
—
4.6
ethoxylate 1
1,2 Propane diol 6
4.5
4.0
3.9
3.1
2.3
Ethanol
3.4
2.3
2.0
1.9
1.2
C 12 -C 18 Fatty Acid 5
2.1
1.7
1.5
1.4
3.2
Citric acid 7
3.4
3.2
3.5
2.7
3.9
Protease 7 (32 g/L)
0.42
1.3
0.07
0.5
1.12
Fluorescent Whitening
0.08
0.2
0.2
0.17
0.18
Agent 8
Diethylenetriamine
0.5
0.3
0.3
0.3
0.2
pentaacetic acid 6
Ethoxylated polyamine 9
0.7
1.8
1.5
2.0
1.9
Grease Cleaning Alkoxylated
—
—
1.3
1.8
—
Polyalkylenimine Polymer 10
Zwitterionic ethoxylated
—
1.5
—
—
0.8
quaternized sulfated
hexamethylene diamine 11
Hydrogenated castor oil 12
0.2
0.2
0.12
0.3
Copolymer of acrylamide and
0.3
0.2
0.3
0.1
0.3
methacrylamidopropyl
trimethylammonium
chloride 13
Antifoam of any of
0.2
0.1
0.2
0.2
0.2
Examples A-C (mixtures
thereof may also be used)
Water, perfumes, dyes,
to 100%
to 100%
to 100%
to 100%
to 100%
buffers, solvents and other
pH 8.0-8.2
pH 8.0-8.2
pH 8.0-8.2
pH 8.0-8.2
pH 8.0-8.2
optional components
Formulation Example 2
Liquid or Gel Detergents
[0106] Liquid or gel detergent fabric care compositions 2A-2E are prepared by mixing the ingredients listed in the proportions shown:
[0000]
Ingredient (wt %)
2A
2B
2C
2D
2E
C 12 -C 15 alkyl polyethoxylate (3.0)
8.5
2.9
2.9
2.9
6.8
sulfate 1
C 11.8 linear alkylbenzene sulfonic acid 2
11.4
8.2
8.2
8.2
1.2
C 14 -C 15 alkyl 7-ethoxylate 1
—
5.4
5.4
5.4
3.0
C 12 -C 14 alkyl 7-ethoxylate 3
7.6
—
—
—
1.0
1,2 Propane diol
6.0
1.3
1.3
6.0
0.2
Ethanol
—
1.3
1.3
—
1.4
Di Ethylene Glycol
4.0
—
—
—
—
Na Cumene Sulfonate
—
1.0
1.0
0.9
—
C 12 -C 18 Fatty Acid 5
9.5
3.5
3.5
3.5
4.5
Citric acid
2.8
3.4
3.4
3.4
2.4
Protease (40.6 mg/g/) 7
1.0
0.6
0.6
0.6
0.3
Natalase 200 L (29.26 mg/g) 14
—
0.1
0.1
0.1
—
Termamyl Ultra (25.1 mg/g) 14
0.7
0.1
0.1
0.1
0.1
Mannaway 25 L (25 mg/g) 14
0.1
0.1
0.1
0.1
0.02
Whitezyme (20 mg/g) 14
0.2
0.1
0.1
0.1
—
Fluorescent Whitening Agent 8
0.2
0.1
0.1
0.1
—
Diethylene Triamine Penta Methylene
—
0.3
0.3
0.3
0.1
Phosphonic acid
Hydroxy Ethylidene 1,1 Di
1.5
—
—
—
—
Phosphonic acid
Zwitterionic ethoxylated quaternized
2.1
1.0
1.0
1.0
0.7
sulfated hexamethylene diamine 11
Grease Cleaning Alkoxylated
—
0.4
0.4
0.4
—
Polyalkylenimine Polymer 10
PEG-PVAc Polymer 15
0.9
0.5
0.5
0.5
—
Hydrogenated castor oil 12
0.8
0.4
0.4
0.4
0.3
Borate
—
1.3
—
—
1.2
4 Formyl Phenyl Boronic Acid
—
—
0.025
—
—
Antifoam of any of the Examples A-C.
0.4
0.3
0.3
0.2
0.3
Water, perfumes, dyes, buffers,
to 100%
to 100%
to 100%
to 100%
to 100%
neutralizers, stabilizers and other
pH 8.0-8.2
pH 8.0-8.2
pH 8.0-8.2
pH 8.0-8.2
pH 8.0-8.2
optional components
1 Available from Shell Chemicals, Houston, TX.
2 Available from Huntsman Chemicals, Salt Lake City, UT.
3 Available from Sasol Chemicals, Johannesburg, South Africa
4 Available from Evonik Corporation, Hopewell, VA.
5 Available from The Procter & Gamble Company, Cincinnati, OH.
6 Available from Sigma Aldrich chemicals, Milwaukee, WI
7 Available from Genencor International, South San Francisco, CA.
8 Available from Ciba Specialty Chemicals, High Point, NC
9 600 g/mol molecular weight polyethylenimine core with 20 ethoxylate groups per —NH and available from BASF (Ludwigshafen, Germany)
10 600 g/mol molecular weight polyethylenimine core with 24 ethoxylate groups per —NH and 16 propoxylate groups per —NH. Available from BASF (Ludwigshafen, Germany).
11 Described in WO 01/05874 and available from BASF (Ludwigshafen, Germany)
12 Available under the tradename ThixinR from Elementis Specialties, Highstown, NJ
13 Available from Nalco Chemicals, Naperville, IL.
14 Available from Novozymes, Copenhagen, Denmark.
15 PEG-PVA graft copolymer is a polyvinyl acetate grafted polyethylene oxide copolymer having a polyethylene oxide backbone and multiple polyvinyl acetate side chains. The molecular weight of the polyethylene oxide backbone is about 6000 and the weight ratio of the polyethylene oxide to polyvinyl acetate is about 40 to 60 and no more than 1 grafting point per 50 ethylene oxide units. Available from BASF (Ludwigshafen, Germany).
Formulation Example 3
Rinse-Added Fabric Care Compositions
[0107] Rinse-Added fabric care compositions 3A-3D are prepared by mixing together ingredients shown below:
[0000]
Ingredient
3A
3B
3C
3D
Fabric Softener Active 1
16.2
11.0
16.2
—
Fabric Softener Active 2
—
—
—
5.0
Cationic Starch 3
1.5
—
1.5
—
Polyethylene imine 4
0.25
0.25
—
—
Quaternized polyacrylamide 5
—
0.25
0.25
Calcium chloride
0.15
0.
0.15
—
Ammonium chloride
0.1
0.1
0.1
—
Antifoam of any of the Examples
0.1
0.1
0.1
0.1
A-C
Perfume
0.85
2.0
0.85
1.0
Perfume microcapsule 6
0.65
0.75
0.65
0.3
Water, suds suppressor,
to 100%
to 100%
to 100%
to 100%
stabilizers, pH control agents,
pH = 3.0
pH = 3.0
pH = 3.0
pH = 3.0
buffers, dyes & other optional
ingredients
1 N,N di(tallowoyloxyethyl)-N,N dimethylammonium chloride available from Evonik Corporation, Hopewell, VA.
2 Reaction product of fatty acid with Methyldiethanolamine, quaternized with Methylchloride, resulting in a 2.5:1 molar mixture of N,N-di(tallowoyloxyethyl) N,N-dimethylammonium chloride and N-(tallowoyloxyethyl) N-hydroxyethyl N,N-dimethylammonium chloride available from Evonik Corporation, Hopewell, VA.
3 Cationic starch based on common maize starch or potato starch, containing 25% to 95% amylose and a degree of substitution of from 0.02 to 0.09, and having a viscosity measured as Water Fluidity having a value from 50 to 84. Available from National Starch, Bridgewater, NJ
4 Available from Nippon Shokubai Company, Tokyo, Japan under the trade name Epomin 1050.
5 Cationic polyacrylamide polymer such as a copolymer of acrylamide/[2-(acryloylamino)ethyl]tri-methylammonium chloride (quaternized dimethyl aminoethyl acrylate) available from BASF, AG, Ludwigshafen under the trade name Sedipur 544.
6 Available from Appleton Paper of Appleton, WI
[0108] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm”.
[0109] All documents cited in the Detailed Description of the Invention are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention. To the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
[0110] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
|
The present application relates to cleaning and/or treatment compositions comprising anti-foams and methods of making and using such compositions. Such compositions encompass consumer products, cleaning and/or treatment compositions, fabric care compositions, or liquid laundry detergents that provide the desired suds profile via the addition of an antifoamer, yet are stable.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to fluid control valves, and more particularly, to an annular valve seat for use in both normal and relatively high temperature environments.
2. Description of the Prior Art
Butterfly and other types of fluid control valves with annular resilient seals are well known and commonly used for controlling the flow of various fluids at ambient or moderate temperatures and modest pressures in a wide variety of industries. Such control valves commonly have a generally annular body defining a fluid flow passage having a valve seat around the flow passage and a metallic flow control disc movably supported in the flow passage for controlling the flow of fluids through the valve. The valve is closed by pressing the disc against the valve seat to prevent the flow of fluid through the valve. Valves used at moderate temperatures and modest pressures commonly use annular resilient seals in the valve seat while metal seals are used at higher temperatures and higher pressures. Such metallic seals usually permit more leakage of fluid than do the resilient seals if used at lower temperatures. For this reason when the normal operating temperature is relatively low resilient seals are commonly used. However, in the petroleum industry there is sometimes the danger of a fire either inside the piping system itself or outside the piping system in the vicinity of the valve. When fire causes the valve temperature to rise to higher levels, the resilient seal of the valve can deteriorate or be destroyed so that it will no longer be effective as a seal.
Some of the prior art valves use a resilient seal when the valve is operating at a lower temperature and have a backup metal seal which moves into operating contact with a valve disc when the resilient seal is damaged. Such a backup valve seat may operate satisfactorily when the resilient seal is completely destroyed, but may have excessive fluid leakage when a portion of the resilient seal remains in the fluid flow passage.
What is desired is a fluid-control valve having both a resilient valve seal and a metal seat that maintain fluid-tight contact with the flow control disc when moderate temperatures are present in the valve, and wherein the metal seat continues to maintain said fluid-tight contact if the resilient seal is partially or completely destroyed.
SUMMARY OF THE INVENTION
The present invention comprises a butterfly or other type of rotary valve with a fire-safe seat assembly for use in a generally annular valve body defining a fluid flow passage. The seat assembly includes a metal seat ring having an annular groove around its radially inward face with a pair of flexible lips forming the walls of the groove, and an annular resilient, non-metallic seal member mounted in the annular groove between the flexible lips. Means are provided for securing the metal seat ring to the valve body adjacent the fluid flow passage, such means causing the flexible lips and a portion of the resilient seal member to press against a flow control element when the flow control element closes the fluid flow passage while operating under moderate temperatures. If higher than normal temperatures should partially or completely destroy the resilient seal member the flexible lips of the metal seat ring continue to press against the flow control element and provide an effective seal. Thus, the flexible lips are pressed against the flow control element irrespective of the presence or absence of the resilient seal member in the groove of the metal seat ring.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation of a butterfly valve employing the features of the present invention.
FIG. 2 is a partial end elevation of the valve taken along the line 2--2 of FIG. 1 showing the valve in the fully closed position.
FIG. 3 is an enlarged fragmentary section of the disc, the body, the retaining ring, and the fire-safe seat assembly of the valve of FIGS. 1 and 2 illustrating the relationship of the elements just prior to the disc engaging the metal seat ring.
FIG. 4 is a view like FIG. 3 illustrating the relationship of the elements of FIG. 3 with the disc partially engaging the metal seat ring.
FIG. 5 is like FIG. 3 showing the disc fully engaged with the resilient seal member and the metal seat ring.
FIG. 6 is a view like FIG. 3 illustrating the relationship of the elements with the flexible seal member either partially or completely destroyed and with the disc fully engaging the metal seat ring.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As illustrated in FIGS. 1 and 2, a butterfly valve 11, incorporating features of the present invention with a bi-directional seat assembly for controlling the fluid flow in either direction, includes a generally annular body 12 defining a fluid flow passage 13, the illustrated body being adapted for insertion between opposed standard pipe flanges (not shown). Rotatably supported in the flow chamber 13 is a flow control disc 17 with a circumferentially sealing surface 18, the surface 18 having a hard facing surface to prevent scratches and abrasions formed as the disc is moved against a valve seat. As best seen in FIG. 2, the disc sealing surface 18 is adapted to cooperate with an annular bi-directional valve seat assembly 19 consisting of a metallic seat ring 23 which carries an annular resilient non-metallic seal member 24. The seat assembly 19 (FIGS. 2, 3-6) resides in an annular seat chamber 25 formed by a counterbore in a retainer ring 30, the retainer ring being releasably secured to the body 12 by capscrews 31 or other suitable means to facilitate quick and easy installation and removal of the seat assembly 19 without necessitating removal of the disc 17 or otherwise disassembling the valve. The capscrews 31 apply a sufficient axial load on the retainer ring 30 to cause an annular inner seat gasket 29 to effect a fluid seal between the seat ring 23 and the valve body 12, and to cause an annular outer seat gasket 35 to effect a fluid-tight seal between the seat ring 23 and the retainer ring 30. When the seat assembly 19 is being installed, the valve should be in its illustrated fully closed condition since the seat assembly is free-floating and thus will center itself diametrically against the disc 17 and thus establish a complete, unbroken sealing interface with the disc surface 18.
The annular metallic seat ring 23 (FIGS. 3-6) is formed of an annular body portion 36 having an annular groove 37 around the radially inward face, and a pair of curved flexible lips 41, 42 forming the walls of the groove 37. The resilient seal member 24, mounted in the groove 37, is formed in the shape of a donut or O-ring and is made of a resilient material such as tetrafluoroethylene (TFE) plastic. The valve seat is assembled by placing the resilient seal member 24 into the groove 37 between the two flexible lips 41, 42 of the annular metallic seat ring 23, and the flexible lips are then swaged over the resilient O-ring, forming a partial metallic encapsulation of the O-ring. After the encapsulation, only a narrow sealing portion of the resilient seal member is left exposed between the two metallic lips 41, 42 of the seat ring.
The metallic seat ring 23 may be made from a work hardenable material such as type 302 stainless steel so that each of the lips is capable of a spring action after it has been swaged into place, the swaging causing the lips to work harden. The spring action is desirable because both the narrow inner sealing portion 24a of the resilient seal member 24, and the open ends 41a, 42a of the seat ring 23, have an inner diameter less than the diameter of the sealing surface 18 of the flow control disc 17, and thus each provides an interference fit with the disc 17.
When the valve disc 18 is moved from the open position (FIG. 3) into contact with the valve seat assembly 19 (FIG. 4) the lip sealing portions 41a, 42a of the metal seat ring 23 and the sealing portion 24a of the resilient seal member 24 contact the sealing surface 18 of the disc 17. Moving the disc 17 into the fully closed position (FIG. 5) causes the sealing portion 24a of the resilient seal member to flatten out and provide a relatively wide band of contact between it and the sealing surface 18 of the disc. The disc provides radially outward pressure on the seal member 24, thereby causing a radially outward portion 24b of the seal member to press against a bottom portion 37a (FIG. 5) of the annular groove in the seat ring 23, thus biasing the seal member 24 tightly against the bottom portion of the groove.
When pressurized fluid in the right portion of the fluid flow passage 13 (as viewed in FIGS. 2-6) causes the upstream lip 42 (FIG. 5) to bend slightly to the left (downstream) and radially outward from disc 17, fluid is forced between the lip 42 and the disc seal surface 18. The pressurized fluid then pushes the resilient seal member 24 downstream against the lip 41, which in turn forces the downstream lip into an increased sealing engagement with the disc 17 forming a metal-to-metal secondary seal and preventing cold flowing of the primary resilient seal member 24. When the valve is exposed to abnormally high temperatures, as in the case of a fire in or around the valve 11, damage to the resilient seal member 24 occurs and the downstream metallic lip 41 becomes the primary seal as shown in FIG. 6.
Pressurized fluid in the left end of the fluid flow passage 13 causes the lip 41 (FIG. 5) to bend slightly to the right (downstream) and radially outward from the disc 17, forcing fluid between the lip 41 and the disc seal surface 18. The pressurized fluid then pushes the resilient seal member 24 downstream against the lip 42, which forces the downstream lip 42 into an increasing sealing engagement with the disc 17 to form a metal-to-metal secondary seal. When the valve is exposed to abnormally high temperatures, as in the case of fire in or around the valve 11, damage to the resilient seal member 24 occurs and the downstream metallic lip 42 becomes the primary seal as shown in FIG. 6.
The disc 17 is mounted in the fluid flow passage 13 (FIGS. 1, 2) by a shaft 46 extending vertically through a bore 47 in the disc. The shaft 46 is secured to the disc 17 by a pair of tapered pins 48 mounted in a pair of transverse bores 52 in the disc with a flat side 48a of each pin pressed firmly against a flat portion 53a, 54a of a corresponding one of a pair of transverse grooves 53, 54 formed in the shaft 46. The space between the upper portion of the shaft 46 and the valve 12 is sealed by a plurality of packed rings 58 (FIG. 2) pressed against a header ring 59 supported on a shoulder 60. The packing rings 58 are squeezed between the header ring 59 and a gland ring 64 to force the rings 58 tightly against the shaft 46 and the valve body 12. A plurality of capscrews 65, extending through a plurality of holes 66 (FIG. 1) in a cover plate 70 and threaded into a plurality of bores 71 in the valve body 12, secure the cover plate 70 to the upper portion of the valve body 12. Tightening of the capscrews 65 causes the cover plate 70 to press the gland ring 64 against the packing rings 58. The space between the lower portion of the shaft 46 and the valve body is similarly sealed by a plurality of packing rings 58a pressed against a header ring 59a by a gland ring 64a, capscrews 65a, and a cover plate 70a.
The upper and lower portions of the shaft 46 (FIG. 2) are supported in the valve body 12 by upper and lower sleeve-type bearings 74, 75, respectively, which bearings can be constructed of a non-galling material with a low coefficient of friction and capable of withstanding exposure to high temperatures. A pair of spacer rings 76, 76a, each mounted between the disc 17 and a corresponding one of the sleeve bearings 74, 75, center the disc 17 in the fluid flow passage 13 by resting against the sleeve bearings 74, 75.
The upper portion of the shaft 46 includes a transverse hole 80 for connecting the shaft 46 to a valve actuator (not shown), which actuator can be secured to the upper end of the valve body by capscrews (not shown) or bolts which fit into a plurality of threaded bores 81 (FIG. 1) in the valve body. An upper portion 12a and a lower portion 12b of the valve body each includes a pair of holes 82 for mounting a plurality of bolts (not shown) for centering the valve body between a pair of standard pipe flanges (not shown).
The present invention provides both a metal-to-metal seal and a resilient sealing surface to insure an extremely low rate of fluid leakage when the valve is operated at moderate temperatures. In case a fire should destroy the resilient sealing material, the metal-to-metal seal provides a secondary sealing action to hold fluid leakage to a low rate. The present invention is especially useful in applications where flammable or other hazardous fluids are being handled.
Some advantages of a valve in accordance with the present invention are that it provides:
1. A seat assembly which is relatively simple to manufacture by swaging the metal seat ring to lock the resilient seal member in place in the groove in the seat ring;
2. A seat assembly which is resistant to blow out of the resilient seal member during high velocity fluid flow;
3. A seat assembly in which the resilient seal member is restricted from cold flowing when exposed to high differential pressures;
4. A single resilient seal ring which is capable of effective sealing irrespective of the direction of fluid flow;
5. A valve sealing mechanism which is effective over a wide range of temperatures; and
6. A valve sealing device having a reliable secondary seal which insures an effective seal despite fire destruction of a resilient primary seal.
Although the present invention has been described as embodied in a butterfly valve, it should be understood that the invention can be utilized in other types of valves, and therefore is not restricted in application to the foregoing constructions.
Although the best mode contemplated for carrying out the present invention has been herein shown and described, it is apparent that modifications and variations may be made without departing from what is regarded to be the subject matter of the invention.
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A fire-safe rotary valve seat assembly for use in pressurized fluid systems subject to fire risk, the seat assembly having both a metal seat ring and an annular resilient non-metallic seal member to provide essentially zero fluid leakage at normal operating temperatures, and the metal seat ring to provide an extremely low rate of fluid leakage in the event high temperature should destroy the flexible seal member. The metal seat ring includes an annular groove around its radially inward face with a pair of flexible lips forming the walls of the groove, and the annular resilient seal member is mounted in the groove between the lips. The lips and the annular resilient seal member both engage a sealing surface on the circumference of a metal valve disc to provide a primary seal for the valve. If the annular resilient seal member is destroyed, the metal lips continue to provide an undamaged secondary seal.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of and is a continuation-in-part of U.S. patent application Ser. No. 10/942,266 filed Sep. 16, 2004, which claims the benefit of and is a continuation-in-part of 10/198,462, filed Jul. 18, 2002, which claims the benefit of U.S. Provisional Application No. 60/306,312 filed Jul. 18, 2001.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to the field of mechanical devices. More specifically, the present invention pertains to counter rotating devices.
[0004] 2. Description of the Related Art
[0005] Devices Other types of counter-rotation devices are know in the art, including those described in U.S. Pat. No. 401,156 discloses two counter-rotating drums one being outside the other, and both rotating about a common axis.
SUMMARY OF THE INVENTION
[0006] The present invention the counter rotation of two closely-spaced toroids—one inside the other.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0007] The present invention is described in detail below with reference to the attached drawing figures, wherein:
[0008] FIG. 1 is an above view of the first embodiment, illustrating the counter-rotation of the two toroid shapes.
[0009] FIG. 2 is cross section of FIG. 1 taken at section 2 - 2 , exposing the wheel/race system of the tear-shaped first embodiment of the present invention.
[0010] FIG. 3A is a perspective view showing the armature of the first embodiment with its attached wheels.
[0011] FIG. 3B shows the inner toroid of the first embodiment with its race. FIG. 3C shows the outer toroid of the first embodiment with its race.
[0012] FIG. 4 is a broken out section showing a cross-sectional view of the wheels and races of the first embodiment.
[0013] FIG. 5 is a cross-sectional view of a second embodiment of the present invention.
[0014] FIG. 6 is a break out section highlighting the wheel/race arrangement of the second-inner-armature embodiment.
[0015] FIG. 7 is a cross-sectional view of section 7 - 7 taken out of the second embodiment shown in FIG. 5 .
[0016] FIG. 8 is a cross-sectional view of a third outer circumscribing armature embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The present invention provides a system and method wherein a toroid shaped surface is placed within another toroid shaped surface, and the two surfaces are dynamically connected in such a way that they will counter-rotate with respect to one another. The outer surface of the interior toroid and the inner surface of the exterior toroid, in embodiments, are in close proximity to one another.
[0018] Although the scope of this invention should not be limited to any particular use, it should be understood that the embodiments of the devices herein could provided self-stabilizing benefits. One known application is in gyrostabilizer devices. See, e.g., U.S. Pat. No. 6,568,291 issued to Inman. Another use is in toys. See, e.g., U.S. Pat. No. 6,899,586 issued to Davis. Other uses would be to make one or both toroids transparent to create an ornamental effect.
[0019] A first embodiment of the invention is shown in detail in FIGS. 1-4 . Looking first to FIG. 1 , the device of the present invention comprises an exterior toroid 10 and interior toroid 12 as illustrated. Though each toroid is disclosed having nominal thickness, it should be understood that these toroids in reality would have some thickness. Perhaps even substantial thickness. Thus, it should be understood that each toroid could have significant thickness and still fall within the scope of the present invention.
[0020] A space 14 exists between the toroids, namely inner surface 16 of the exterior toroid 10 and the outer surface 18 of inner toroid 12 .
[0021] A rotation device (not shown) is provided within the hole 20 defined through the two toroids. This rotation device rotates the exterior toroid in one direction and the interior toroid in a counter direction to that of the exterior toroid.
[0022] In embodiments, the toroids can be driven using a driving mechanism. The likely embodiment of the driving mechanism is an electric motor (not shown), or some sort of mechanical device such as a hand cranked mechanism (not shown) or a bicycle-type foot actuated drive system (also not shown).
[0023] Referring to FIG. 2 , also shows a more detailed view of a counter-rotation enabling set 19 . An armature 26 and bearing set 22 create a stationary base around which the toroids counter rotate.
[0024] To begin the counter-rotational process, a rotational driving force is applied to the exterior toroid by one of the means described above. In the preferred embodiment to outer toroid 10 . More specifically, onto the outside of a race 30 on outside toroid. The device used to drive outside toroid 10 would likely be positioned within opening 20 . This, however, is a matter of choice. The driving device could be located in a location other than opening 20 .
[0025] Instead of mechanically creating this rotational force to outer toroid 10 , other means could be used. For example, the desired counter rotation could be created by manually spinning the outer toroid 10 .
[0026] In the preferred embodiment, armature 26 remains stationary. It may either be fixed to some stationary component of the motor, or fixed in some other fashion. Because the armature 26 is fixed, the rotation of the outer toroid necessarily causes the rotation of the inner toroid in the opposite direction.
[0027] In some embodiments, the interior and exterior toroids may be made of vulcanized rubber. Other materials, however, will be known to those skilled in the art that could be used alternatively, e.g., metals, plastics, glass, etc., Thus, the scope of the invention should not be limited to any particular material.
[0028] The device and operation of the first embodiment of FIGS. 1-4 will now be discussed in more detail. FIG. 1 is kind of an X-ray view of the present invention. From this figure, it may be seen that the device of the first embodiment comprises outer toroid 10 and inner toroid 12 . Also shown in this figure is that the device 6 includes an armature 26 which enables counter rotation of the toroids, one within the other.
[0029] Referring now to cross-sectional FIG. 2 , we are able to see the inner workings of the device. This figure is actually taken at section two in FIG. 1 . FIG. 2 , however, makes it evident how the device works. The counter rotation between toroids 10 and 12 is enabled by a counter rotation set 19 . Counter rotation set 19 comprises numerous parts. First, the device includes a race 30 for outer toroid 10 . This race 30 has an inner rim which defines opening 20 . Race 30 also has an outer edge of the race 31 . The open center defined by the inside rim of race 30 may be viewed by referring back to FIG. 1 . Race 30 also includes a rim 34 . Rim 34 is also defined on race 30 and is used to retain an armature wheel set, as will be described hereinafter.
[0030] An inner race assembly 32 is also presented as part of the first embodiment. This race assembly 32 comprises an outer edge 33 and terminates in a V-shaped portion 35 , outer surface of which receives the wheels on an armature 26 .
[0031] Armature assembly 26 may be seen in more detail in FIG. 3A . The figure shows the armature before it is assembled into the device 6 between the two toroids. FIG. 3A shows a plurality of wheels 22 which are part of the armature assembly 26 are mounted on a plurality of angled shafts 24 . These angled shafts 24 are all welded or otherwise fixed onto a ring member 28 at an acute angle to one another.
[0032] FIG. 4 shows the wheels and races of the first embodiment in more detail because it is a broken out section. Some features disclosed in this figure not yet disclosed are that the plurality of wheels 22 each possess a retaining mechanism (e.g. a nut) and a sleeve 38 with an enlarged opposing section. Sleeve 38 and nut 36 serve to maintain the wheel on the armature in a way which will be well known to those skilled in the art. Similar wheels have, e.g., been used on skateboards in the prior art. Here, however, these wheels will be used to enable the counter rotation of toroid 10 relative to toroid 12 .
[0033] Armature 26 is the only part of device 6 which will remain stationary during operation of the device. As may be seen from FIG. 2 , each of the wheels is pinned between inside race 32 and outer toroid race 30 . The plurality of wheels 22 are able to roll freely on armatures 26 .
[0034] The races 32 and 30 of the present invention may be seen from another perspective in FIGS. 3B and 3C respectively. These features are sections drawn to help in the understanding of how the races are configured on the toroid sections. As may be seen with respect to inner toroid 12 in FIG. 3B , the inner race 32 is what will receive the plurality of wheels 22 from inside. Referring then to FIG. 3C , we see that the race 30 on outer toroid 10 contains and engages the plurality of wheels 22 from the outside. Viewing these FIGS. 3B and 3C while reflecting back on FIG. 2 helps in this understanding. In FIG. 2 we see that if race 32 were rotated in such a way that it is coming out of the page, the wheels 22 would drive race 30 into the page. The reverse of this principal is also true. If race 30 is rotationally driven into the page, the wheels 22 would drive race 32 in a direction which would be out of the page.
[0035] In operation, armature 28 will be fixed to a portion of the motor, or some other stationary thing. The manner in which armature 28 is fixed is not shown in any of the figures, but one skilled in the art will understand that this may be done but simply welding or linking armature 28 to something stationary.
[0036] Races 30 and 32 are fixed to toroids 10 and 12 respectively. Thus, because these races counter rotate, the toroids also will rotate opposite one another. Considering this in a more three dimensional sense, race 30 would be traveling counter clockwise around an axis through the center of hole 21 whereas race 30 (as well as toroid 10 ) would be rotating in a clockwise fashion.
[0037] In the case that an electric motor is used, a wheel may be used to drive the outer toroid. The driving motor and driving wheel are not shown, but it will be understood to one in the art that motors able to drive rotating wheels are commercially available, and could easily be located and installed by one skilled in the art to impart rotation to the outside of race 30 , or to any other part of outside toroid 10 . It is preferable that the driving wheel would bear on the outside of race 30 of the outer toroid 10 because the outermost surface of the race 30 is exposed, and also located in close proximity to opening 21 . Though the driving wheel is not shown, if such a wheel were to apply a force conceptionally pushing race 30 into the page, race 33 which is fixed to the inner toroid 12 would be forced to come out of the page, thus creating counter rotation.
[0038] Though the use of an electric motor and driving wheel has been described in most specificity herein, other means to drive the outer toroid could be used as well, such as mechanical pedaling devices, or simply manually rotating the outer race or toroid. Thus, all other driving means would also be included within the scope of the present invention.
[0039] It is also possible, in other embodiments, that the armature 26 , not be fixed at all. In this case, the two toroids would still be able to rotate relative to one another. In such a case the armature, even though not fixed, would still enable the outer and inner toroids to rotate relative to one another. In the case that outer toroid 30 is angularly accelerated, the inner toroid 12 would likely rotate with it to a certain extent, but mostly not. This is because inner toroid 12 has significant mass and is able to rotate freely on the wheels 22 . Because it is not being directly driven by anything, it would substantially drag behind the angular speed of the forcibly driven outer toroid. This difference in angular velocities, even though the inner toroid would rotate in the same direction as the outer toroid, would still create a counter rotation, relatively speaking. Ultimately the rotational speed of the inner toroid would be significantly less than the speed of the outer toroid. Thus, the inner toroids rotation relative to that of the outer toroid would be a relative counter rotation. Even if this statement is semantically incorrect, the term “counter rotation” as used in this specification and in relation to this application is to be defined as including differences in angular velocity between the two toroids. Though it will typically be desirable that armature 26 be stationary, and that the two toroids rotate in opposite angular directions, the device will still work even if the armature is not stationary. In such a case, the two toroids will rotate in the same angular direction, but will have substantially different speeds. This speed difference will result in the inside surface of the outer toroid still moving relative to the outer surface of the inside toroid. In the preferred embodiment, however, the armature is secured in some fashion to make it easier to create greater counter rotation with less effort.
[0040] An alternative embodiment 40 of the present invention is shown in FIGS. 5-7A . Like the first embodiment, second embodiment 40 has an inner toroid 60 which is located inside an outer toroid 58 . Device 40 , however, has a different kind of armature 42 . Armature 42 is internally disposed and has a D-shaped cross sectional appearance. Because it is located inside the toroids, an innermost surface 52 of the armature 42 defines the center hole of the device of the second embodiment 40 . Internal armature 42 has disposed thereon a plurality of wheels 44 . These wheels are received by a race 46 on the inner toroid. On the outer toroid, a race 48 is presented. The plurality of wheels 44 are received by races 46 and 48 to enable counter rotation much like the first embodiment. Unlike with the first embodiment, however, the internal armature 42 possesses a straight cross sectional portion 50 , a curved inner most portion 52 , and an angled wheel support section 54 which collectively create a D-shaped cross section. FIG. 5 shows all these features in cross section. The curved inner most portion 52 defines the hole through the device. The angled wheel support, in cross section, is a straight short portion on which the angled shaft 56 are welded or otherwise fixed.
[0041] The outer toroid 58 and inner toroid 60 will counter rotate with this embodiment in much the same way in which the toroids of the first embodiment 6 . Armature 42 is the only part shown in FIG. 5 that remains stationary. As with the earlier embodiment, this armature 42 could either be connected to the engine in some fashion, or fixed to some other stationary thing in a manner that will be within the skill of those skilled in the art. Like with the last embodiment, a wheel could drive the device by engaging an outer portion 55 of the race on the outer sleeve 58 . Other means to rotate the outer toroid 58 could be employed as well. For example, the user could simply rotate the outer toroid 58 by pushing it with his hands. Regardless, upon the rotation of outer toroid 58 , inner toroid 60 will automatically counter rotate because of the rotation of the wheels. Thus, just like the last embodiment, rotation of the outer sleeve 58 in a counter clockwise manner will result in the clockwise rotation of inner sleeve 60 and vice versa. Even if done at moderate speeds a counter-rotation is created.
[0042] FIG. 6 shows how the plurality of wheels 44 are included between the races to create the desired counter rotation. The fundamentals of this counter rotation may also be seen in FIG. 7A where, conceptually is easily able to perceive that the movement of race 48 on outer toroid 58 into the page will create a resultant compelling of race 46 out of the page. This is how the counter rotation is accomplished with this second embodiment—much like occurred with the first embodiment.
[0043] Disclosed in FIGS. 7B and 8 is a third embodiment 70 . Third embodiment 70 includes an outer toroid 72 and an inner toroid 74 just like the first two embodiments. Unlike these embodiments, however, an armature 76 is provided which is disposed on the outside of the toroids. Thus, these semicircular and external to the entire device 70 . It is essentially the same as the second embodiment, except that the third embodiment armature 76 of FIG. 7B is basically an inverted version of the former version of the second embodiment in FIG. 7A . Inverted such that the armature exists on the periphery of the device instead of the interior.
[0044] The second embodiment and third embodiment armatures are each more useful in certain situations. For some uses the armature and motor were more apt to be included within the hole of the device. In these cases, the centrally located armature 42 of the second embodiment would be more useful because the armature and races would be more accessible to the motor and drive wheel (not shown) which would be located near the hole. The third embodiment, however, might be more useful in a situation where it is desired that the motor and drive wheel are located somewhere external to the device 70 . This is because the armature 76 , which is the stationary component of the device, is obviously more accessible from the outside of the toroid with this arrangement. Conversely, the interior armature 42 of device 40 as the only stationary component is more accessible from the middle of the toroid.
[0045] Now moving to more specifics regarding the third embodiment, we see that it's outside armature has a straight portion 86 , a linear cross sectional portion 88 , and an angled wheel bearing portion 90 , which is a short angled plate on which the wheel shafts 92 are fixed. The plurality of wheels 82 on this embodiment 70 rotate about the shafts 92 and enable counter rotation much like that disclosed in the second embodiment.
[0046] As can be seen, the present invention and its equivalents are well-adapted to provide a new and useful counter-rotation device. Many different arrangements of the various components depicted, as well as components not shown, are possible without departing from the spirit and scope of the present invention.
[0047] The present invention has been described in relation to particular embodiments, which are intended in all respects to be illustrative rather than restrictive. Alternative embodiments will become apparent to those skilled in the art that do not depart from its scope. Many alternative embodiments exist but are not included because of the nature of this invention. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the present invention.
[0048] It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims. Not all steps listed in the various figures need be carried out order described.
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A counter-rotation device is disclosed that has two hollow toroids. One toroid is placed within the other. The device can serve a multitude of purposes, e.g., whenever two counter rotating objects are needed for mechanical, electrical, or ornamental purposes.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an imaging device for imaging an object using two-dimensional imaging elements. Furthermore, the present invention relates to a particle image capturing apparatus for imaging particles in an optical cell moving at high speed together with the medium.
[0003] 2. Description of the Related Art
[0004] Conventional an imaging devices are known, such as digital cameras and the like, which capture the image of an object using an area sensor (two-dimensional imaging element such as a CCD or the like) to produce image data. U.S. Pat. No. 5,721,433 discloses a particle image analyzer capable of analyzing particle images obtained by sequentially imaging particles of a particle suspension fluid flowing within an optical gel and moving through an imaging region, and displaying a calculated distribution map of the shape parameters such as the degree of roundness and the like so as to analyze the shape and the like of micro particles.
[0005] When interlace-type CCD area sensors for sequentially scanning odd pixels (ODD field) and even pixels (EVEN field) are used as the imaging elements of the particle image analyzer of U.S. Pat. No. 5,721,433, a striped pattern is introduced into the image when the area sensor is optically exposed during the EVEN field period. In general, the ODD field period of the area sensor is {fraction (1/60)} of a second, and the EVEN field period is {fraction (1/60)} of a second. Accordingly, when the particle image analyzer uses interlace-type CCD area sensors, it is difficult to image particles moving through the imaging region during the imaging intervals since the imaging interval must be approximately {fraction (1/30)} of a second.
SUMMARY
[0006] The object of one embodiment of the present invention is to provide an imaging device which improves the probability of imaging each object even when imaging a plurality of objects moving at high speed.
[0007] The first aspect of the present invention relates to an imaging device comprising: a first two-dimensional image sensing elements; a second two-dimensional image sensing element; an optical system for forming identical optical images on the first and second image sensing elements; a first shutter means for controlled exposure of the first image sensing element from the optical system; a second shutter means for controlled exposure of the second image sensing element from the optical system; and a control means for driving the first image sensing element based on field signals sequentially repeating ODD field period and EVEN field period, driving the second image sensing element based on field signals having a different phase than the first image sensing element, and controlling the operation of the first shutter means and second shutter means so as to expose with light from the optical system an image sensing element having the ODD field period among the first and second image sensing elements.
[0008] The second aspect of the present invention relates to an imaging device comprising: a plurality of two-dimensional image sensing elements; an optical system for forming optical images on the respective image sensing elements; and a drive control means for driving the plurality of image sensing elements with respectively different timings, and controlling the operation of electronic shutters of the respective image sensing elements so as to expose one image sensing element among the plurality of image sensing elements.
[0009] The third aspect of the present invention relates to a particle image capturing apparatus for imaging particles comprising: a flow cell for forming a flow of a particle suspension; a light source for irradiating the particle suspension flow with light; a first two-dimensional image sensing elements driven based on field signals sequentially repeating the ODD field period and EVEN field period; a second two-dimensional image sensing element driven based on field signals having a phase different than that of the first two-dimensional image sensing element; an optical system for forming identical optical images of the particle suspension flow on the first and second two-dimensional image sensing elements; a first shutter means for exposing the first two-dimensional image sensing element with light from the optical system when the first two-dimensional image sensing element has an ODD filed period; and a second shutter means for exposing the second two-dimensional image sensing element with light from the optical system when the second two-dimensional image sensing element has an ODD filed period.
[0010] The fourth aspect of the present invention relates to a particle image capturing apparatus for imaging particles comprising: a flow cell for forming the flow of a particle suspension fluid; a light source for irradiating the particle suspension fluid; a first two-dimensional image sensing element; a second two-dimensional image sensing element; an optical system for forming identical optical images of particles in the particle suspension flow on the first and second particle image sensing elements; a first shutter means for controlled exposure of the first image sensing element from the optical system; a second shutter means for controlled exposure of the second image sensing element from the optical system; and a drive control means for driving the first image sensing element based on field signals sequentially repeating ODD field period and EVEN field period, driving the second image sensing element based on field signals having a different phase than the first image sensing element, and controlling the operation of the first shutter means and second shutter means so as to expose with light from the optical system an image sensing element having the ODD field period among the first and second image sensing elements.
[0011] The fifth aspect of the present invention relates to a particle image capturing apparatus comprising: a first two-dimensional image sensing element; a second two-dimensional image sensing element; an optical system for forming identical optical images of the particle on the first and second image sensing elements; and a drive control means for driving the first and second image sensing elements with different timings, and controlling the operation of electronic shutters of the respective image sensing elements so as to expose one or another of the first or second image sensing elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows the structure of an embodiment of an imaging device;
[0013] FIG. 2 shows the field signals of a first CCD and a second CCD;
[0014] FIG. 3 shows the structure of a particle image capturing apparatus using an embodiment of the imaging device;
[0015] FIG. 4 is a control block diagram of the particle image capturing apparatus;
[0016] FIG. 5 shows the particle image analyzer using the particle image capturing apparatus;
[0017] FIG. 6 is a control block diagram of the particle image analyzer;
[0018] FIG. 7 shows the flow of the analysis controls of the particle image analyzer;
[0019] FIG. 8 illustrates the calculation of the surface area S and the circumference length L of the particle image;
[0020] FIG. 9 shows a second embodiment of the measuring unit of the particle image capturing apparatus;
[0021] FIG. 10 shows the optical cell of the measuring unit;
[0022] FIG. 11 shows the structure light source unit for zonal light exposure; and
[0023] FIG. 12 shows the A-A cross sectional view of FIG. 11 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] The structure of an embodiment of the imaging device 1 is shown in FIG. 1 . The imaging device 1 is provided with an optical system 2 , first CCD 6 , second CCD 7 , a first CCD drive circuit 8 for driving the first CCD, a second CCD drive circuit 9 for driving the second CCD 7 , and a standard crystal oscillator 10 . The optical system 2 is provided with an objective lens 3 for collecting the image of an object, and a half-mirror 4 for dividing the light from the objective lens 3 . The first CCD 6 and the second CCD 7 are both interlace-type CCD area sensors provided with an electronic shutter. The exposure timing of the electronic shutter of the first CCD 6 is controlled by the first CCD drive circuit 8 . The exposure timing of the electronic shutter of the second CCD 7 is controlled by the second CCD drive circuit 9 .
[0025] The first CCD drive circuit 8 for driving the first CCD 6 is provided with a synchronizing signal generator 8 a for generating synchronizing signals such as a vertical synchronizing signal VD and horizontal synchronizing signal HD based on the signal of the standard crystal generator 10 , timing generator 8 b for receiving the input of the vertical synchronizing signal VD and horizontal synchronizing signal HD output from the synchronizing signal generator 8 a and generating various types of timing signals used for the first CCD 6 , and a driver 8 c for receiving the timing signals output from the timing generator 8 b and driving the first CCD 6 by providing a vertical transmission pulse, horizontal transmission pulse, and shutter pulses (electronic shutter starting pulse for the first CCD 6 ) for discharging accumulated signal loads and starting a new exposure. The signal processing system of the output signals of the first CCD 6 are omitted from the drawing. The second CCD drive circuit 9 for driving the second CCD 7 is similarly provided with a synchronizing signal generator 9 a for generating synchronizing signals such as a vertical synchronizing signal VD and horizontal synchronizing signal HD, timing generator 9 b, and driver 9 c.
[0026] The first CCD 6 is driven based on the field signal which has the reverse phase of the second CCD 7 . In FIG. 2 , FLD 1 is the field signal for driving the first CCD 6 , and FLD 2 is the field signal for driving the second CCD 7 . FLD 1 and FLD 2 are field signals which alternatingly repeat the ODD field and EVEN field. The field signal FLD 1 and the field signal FLD 2 have the same frequency, and their phase difference is π. The field signal FLD 1 has a phase which is the reverse that of the field signal FLD 2 . Therefore, when the field signal of the first CCD 6 is EVEN, the field signal of the second CCD 7 is ODD, and conversely, when the field signal of the first CCD 6 is ODD, the field signal of the second CCD 7 is EVEN. Either the first CCD 6 or the second CCD 7 are normally in a state capable of image sensing since they are driven by the field signals FLD 1 and FLD 2 .
[0027] Although the first CCD 6 and the second CCD 7 are driven based on field signals having reverse phases in the present embodiment, they also may be driven based on field signals having different phases.
[0028] The structure of an embodiment of the particle image capturing apparatus 11 using the imaging device 1 is shown in FIG. 3 . The particle image capturing apparatus 11 is provided with a measuring unit 12 provided with the imaging device 1 , input unit 23 , display unit 24 , and control unit 25 . The measuring unit 12 is provided with a particle suspension fluid 13 accommodated in a particle suspension bottle, suction pipette 14 , sample filter 15 , sample charging line 16 , sheath syringe 17 , flow cell 18 , sheath fluid bottle 19 , sheath fluid chamber 20 , waste fluid chamber 21 , light source (strobe) 22 , and imaging device 1 . The input unit 23 is an input device for performing various types of input operations and command operations, and is a keyboard, mouse and the like. The display unit 24 is a display unit such as a CRT display or the like. A touch panel type display may be used as the input device 23 and the display device 24 . Furthermore, since the structure of the imaging device 1 is shown in FIG. 1 , the internal structure of the imaging device 1 is omitted from the drawing.
[0029] FIG. 4 is a control block diagram of the particle image capturing apparatus 11 . The control unit 25 is provided with a central processing unit (CPU) 26 , memory 27 , measuring unit drive control circuit 28 , and signal processing circuit 29 . The memory 27 is provided with RAM, ROM, hard disk and the like. The memory 27 accommodates drive control programs for the measuring unit, signal processing programs for processing signals (particle image data) from the first CCD 6 and second CCD 7 and the like. The CPU 26 executes the drive control of the measuring unit through the measuring unit drive control circuit 28 based on the drive control programs accommodated in the memory 27 . The CPU 26 processes signals from the first CCD 6 and the second CCD 7 through the signal processing circuit 29 based on the signal processing program accommodated in the memory 27 . The particle image data from the first CCD 6 and the second CCD 7 are converted to digital data by an A/D converter of the signal processing circuit 29 , and thereafter stored in the memory 27 .
[0030] The imaging of the particle image in the measuring unit 12 of FIG. 3 is performed as described below. First, the particle suspension fluid 13 accommodated in the particle suspension bottle is suctioned by the suction pipette 14 , passed through the sample filter 15 , and delivered to the sample charging line 16 at the top part of the flow cell 18 . Coarse particles and debris in the suspension fluid are removed by the sample filter 15 so as to not clog the narrow flow cell 18 of the flow path. Furthermore, the sample filter 15 is also effective in unbinding coarse clumps. When the assayed particles are semitransparent, an appropriate staining of the particles may be performed.
[0031] The suspension fluid 13 delivered to the charging line 16 is introduced to the flow cell 18 by the operation of the sheath syringe 17 , and the particle suspension fluid 13 is extracted a little at a time from the tip of the sample nozzle 18 a. At the same time, the sheath fluid is also delivered to the flow cell 18 from the sheath fluid bottle 19 through the sheath fluid chamber 20 . As a result, the particle suspension fluid 13 is encapsulated in the sheath fluid, and the suspension fluid is constricted as it flows within the flow cell 18 via flow dynamics, and is discharged to the waste chamber 21 .
[0032] The suspension flow in the flow cell 18 is periodically irradiated each {fraction (1/60)} second by a pulse of light from the light source (strobe) 22 . In this way a still image of a particle is introduced each {fraction (1/60)} second to the optical system 2 of the solid-state imaging device 1 . The still image is input to the first CCD 6 and second CCD 7 through the optical system 2 . The first CCD 6 is driven by a field signal having the reverse phase of the second CCD 7 as described previously. Therefore, the image of the particle input by the optical system 2 is sensed by the CCD which has the ODD field signal among the first CCD 6 and the second CCD 7 .
[0033] Although a first CCD drive circuit 8 and a second CCD drive circuit 9 are used as exposure control means in the above embodiment, the exposure timing of the first CCD 6 and second CCD 7 also may be controlled by the control unit 25 . Furthermore, although an electronic shutter is used as a shutter means for controlling the exposure of the first CCD 6 and second CCD 7 , a mechanical shutter also may be used.
[0034] Although the first CCD 6 and second CCD 7 are driven based on field signals having reverse phases, they also may be driven based on field signals having different phases.
[0035] The structure of a particle image analyzer 30 provided with the particle image capturing apparatus 11 is shown in FIG. 5 . The particle image analyzer 30 is provided with the particle image capturing apparatus 11 , image processing device (personal computer) 31 , operation input unit 32 for inputting various types of operations and the like, and display unit 33 . The operation input unit 32 is a keyboard (or mouse), and the display unit 33 is a display.
[0036] FIG. 6 is a block diagram of the image processing system in the particle image analyzer; the particle image data from the particle image capturing apparatus 11 is processed in the image processing device (personal computer) 31 , and displayed on the display 33 (display unit) functioning as a display device. The image processing device 31 is provided with a CPU 34 , memory unit 35 , and signal processing circuit 36 . The memory unit 35 is provided with a RAM, ROM, hard disk and the like, and stores analysis programs for executing the image processes described below.
[0037] The image processing sequence of particle image data of each {fraction (1/60)} second is shown in FIG. 7 . The image processing device 31 executes the processes of steps S 1 through S 12 shown in FIG. 7 .
[0038] The particle image signals from the first CCD 6 and second CCD 7 are subjected to A/D conversion by the signal processing circuit 36 of the image processing device 31 , to obtain particle image data (step S 1 ). First, the obtained image data are subjected to background correction to correct unevenness in the intensity of light (shading) irradiating the suspension fluid flow (step S 2 ).
[0039] Specifically, image data obtained by light exposure when particles are not moving through the flow cell 18 are collected prior to the measuring, and these image data and the image data of the actual particle image screen are compared. Then, a contour enhancement process is executed to accurately extract the contour of the particle image (step S 3 ). Specifically, the generally well-known Laplacean enhancement process is executed.
[0040] Next, the image data are binarized at an appropriate threshold level (step S 4 ). Then, a determination is made as to whether or not the binarized particle image has an edge point, and information on a possible edge point adjacent to the observed edge point. That is, a chain code, is generated (step S 5 ). Thereafter, the particle image is subjected to edge tracing while referring to the chain code, and the total number of pixels, total number of edges, and number of inclined edges of each particle image are determined (step S 6 ).
[0041] If an image processing device capable of high-performance pipeline processing is used, the aforesaid image processing of a screen imaged every {fraction (1/60)} second can be accomplished in real time. Furthermore, the particle image can be extracted from the imaged frame, and the extracted particle image can be stored in the image memory of the memory unit 35 of the image processing device 31 (step S 7 ).
[0042] When the imaging ends (step S 8 ), particle characteristics parameters such as circular equivalent diameter (granularity) and roundness and the like are calculated as described below (step S 9 ). First, the projection surface area S and circumferential length L of each particle image are determined from the total number of pixels, total number of edges, and number of inclined edges of each particle image using the equations below.
[0043] As shown in FIG. 8 , the surface area S within the frame and the length of the frame (period length L) which can be connected to the center of the edges of the circumferences of binary images can be expressed by equations (1) and (2) below when the surface area per unit pixel is “1”.
Surface area S=total number of pixels−(total edges×0.5)−1 (1)
Circumferential length L=(total number of edges−number of inclined edges)+(number of inclined edges×2 1/2 ) (2)
[0044] Then, the circular equivalent diameter is determined using the surface area S and circumferential length L. The circular equivalent diameter is the diameter of a circle having the same surface area as the projection image of the particle, and is expressed by equation (3). The roundness is a value defined by equation (4); the roundness is “1” when the particle image is circular, and the roundness value becomes smaller the larger the irregularities of the exterior edge of the particle image.
Circular equivalent diameter=(particle projection image area/π)½×2 (3)
Roundness=(circumferential length of a circle having a projection surface area value identical to the particle image)/(circumferential length of the particle image) (4)
[0045] When the circular equivalent diameter (granularity) and roundness of each particle image is calculated in this way, then a required scattergram and histogram are created based on commands from the keyboard 32 and displayed on the display 33 (step S 10 ).
[0046] When analysis items and analysis regions are specified from the keyboard 32 , these items and regions of the displayed scattergram and histogram are analyzed, that is, various analysis data, such as average value, standard deviation, variable coefficient, median value, mode value, 10% cumulative value, 50% cumulative value, 90% cumulative value and the like are calculated and the calculation results are displayed (steps S 11 , S 12 ).
[0047] FIG. 9 shows the structure of a second embodiment of the particle image capturing apparatus. FIG. 10 shows details of the optical cell and the particle suspension fluid discharge nozzle of FIG. 9 . The first CCD drive circuit for driving the first CCD 6 and the second CCD drive circuit fro driving the second CCD 7 are omitted from FIG. 9 since they are identical to the first CCD drive circuit 8 and second CCD drive circuit 9 of FIG. 1 .
[0048] The measuring unit 40 is provided with a first light source unit 41 having a red semiconductor laser light source with a wavelength of 660 nm, conical exterior surface reflective mirror 42 , conical interior surface reflective mirror 43 , ring mirror 44 , conical interior surface reflective mirror 45 , optical cell 46 , objective lens 49 , dichroic mirror 50 , lens 51 , mirror 52 , pinhole plate 53 , collimator lens 54 , bandpass filter 55 , photosensor element (photomultiplier tube) 56 , imaging control unit 57 , second light source unit 58 having a pulse semiconductor light source with a wavelength of 870 nm, half-mirror 59 , focusing lens 60 , half-mirror 61 , mirror 62 , first CCD 63 , and second CCD 64 .
[0049] First, when a laser beam of 600 nm wavelength is emitted from the first light source unit 41 , the laser light is converted to zonal light by the conical exterior surface reflective mirror 42 and the conical interior surface reflective mirror 43 . The zonal light is guided to the conical interior surface reflective mirror 45 by the ring mirror 44 , and converges at the detection region 48 of FIG. 10 . In FIG. 10 , when the particle in the suspension fluid discharged from the nozzle 47 in the optical cell 46 reaches the detection region 48 , the particle is excessively irradiated by the 600 nm zonal light. The scattered light (600 nm) from the excessively irradiated particle is reflected by the dichroic mirror 50 through the objective lens 49 , and enters the photosensor element (photomultiplier tube) 56 through the lens 5 1 , mirror 52 , pinhole plate 53 , collimator lens 54 , and bandpass filter 55 . In this way the photosensor element 56 measures the intensity of the scattered light from the detection region 48 . When the scattered light from the detection region 48 is detected by the photosensor element 56 , the imaging control unit 57 determines the imaging object particle when the scattered light intensity is in a predetermined range, and the pulse semiconductor laser light source (wavelength: 870 nm) of the second light source unit 58 generates a pulse. The pulse semiconductor laser light having a wavelength of 870 nm is reflected by the half-mirror 59 . The light reflected by the half-mirror 59 passes through the dichroic mirror 50 , and converges at the detection region 48 via the objective lens 49 . The dichroic mirror 50 transmits light having a wavelength of 870 nm, and reflects light having a wavelength of 600 nm.
[0050] The scattered light from the irradiated particle enters the first CCD 63 through the objective lens 49 , dichroic mirror 50 , half-mirror 59 , objective lens 60 , and half-mirror 61 . The light reflected by the half-mirror 61 enters the second CCD 64 through the mirror 62 . This assay unit 40 is capable of high efficiency imaging of particles since it detects and images particles moving in the imaging region. Although the detection region 48 shown in FIG. 10 is set so as to closely match the imaging region, the imaging region also may be set to the left side of the detection region 48 in FIG. 10 (downstream in the medium discharge direction from the nozzle 47 ).
[0051] Furthermore, a zonal irradiating light source unit having the structure shown in FIGS. 11 and 12 may be used as the second light source unit 58 . FIG. 11 is a cross sectional view of the structure of a zonal irradiation light source unit, and FIG. 12 is an A-A cross sectional view of FIG. 11 .
[0052] In FIGS. 11 and 12 , a multimode optical fiber 72 is inserted into a through-hole provided on the same axis as the center axis of a cylindrical body 71 . The multimode optical fiber 72 has a core 73 and clad 74 . The body 71 is provided with six through-holes parallel to the through-hole disposed on the same axis as the center axis of the body 71 on the circular circumference centered on the center axis of the body 71 , and provided at the end of these respective through-holes are laser light sources 76 a, 76 b, 76 c, 76 d, 76 e, 76 f, and collimator lenses 77 a, 77 b, 77 c, 77 d, 77 e, and 77 f (refer to FIG. 12 ). inside these through-holes are provided light source drive circuit boards 75 a, 75 b, 75 c , 75 d, 75 e, and 75 f (boards 75 b, 75 c, 75 d, 75 e, and 75 f are not shown).
[0053] The light-emitting sides of the through-holes provided on the same axis as the center axis of the body 71 are provided with three collimator lenses 79 a, 79 b, and 79 c. A concave mirror 78 is provided at the left endface of the body 71 shown in FIG. 11 . The optical axis of the multimode optical fiber 72 matches the optical axis of the concave mirror 78 , that is, the light receiving opening is arranged at the focus point of the concave mirror 78 .
[0054] A multimode optical fiber having a core diameter of 800 □m is used as the multimode optical fiber 72 . Furthermore, Pulse semiconductor lasers are used as the laser light sources 76 a through 76 f.
[0055] In the aforesaid structure, the plurality of light fluxes emitted from the laser light sources 76 a through 76 f are converted parallel light which is parallel to the optical axis of the mirror 78 by the collimator lenses 77 a through 77 f. The parallel light is condensed by the concave mirror 78 and enters the light receiving end of the multimode optical fiber 72 from different directions at predetermined identical entrance angles. Since the length of the optical paths are mutually identical from the laser light sources 76 a through 76 f to the multimode optical fiber 72 , all of the light flux enters the light receiving opening having the same spot diameter.
[0056] The multimode optical fiber 72 mixes the plurality of entering light fluxes and reduces the coherence and smoothes the light intensity distribution and emits the radiant zonal light fluxes from the emission opening to the three collimator lenses 79 a, 79 b, and 79 c. The collimator lenses 79 a, 79 b, and 79 c convert the radiant zonal light fluxes from the optical fiber 72 to parallel light flux having a single optical axis.
[0057] From the perspective of good zonal light formation, the plurality of laser light sources are arranged on the circumference centered on the optical axis of the multimode optical fiber 72 such that the spacing of the adjacent laser light sources are equidistant. The number of zonal light forming light sources, that is, the laser light sources emitting light of the zonal light wavelength, is desirably four to eight, and preferably 5 to eight.
[0058] According to this structure, coherence can be reduced and zonal light effectiveness improved by the multimode optical fiber using a plurality of laser light sources which emit light flux of a predetermined wavelength. That is, when a particle imaged by zonal light is irradiated, optical resolution is improved since only the light flux entering at an angle to the particle is used. Furthermore, the detection signal to noise ratio is improved by using laser light to reduce coherence.
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The present invention relates to an imaging device comprising a plurality of two-dimensional image sensing elements, optical system for forming optical images on the respective image sensing elements and drive control means for driving the plurality of image sensing elements with respectively different timings, and controlling the operation of shutters of the respective image sensing elements so as to expose one image sensing element among the plurality of image sensing elements.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of U.S. Ser. No. 08/652,764, filed May 23, 1996, now U.S. Pat. No. 5,800,556.
FIELD OF THE INVENTION
The present invention relates to an adaptor for converting a bipolar shell trial into a unipolar head trial.
BACKGROUND OF THE INVENTION
A successful hip replacement or arthroplasty procedure results, in part, from selection of prosthetic joint components that are dimensioned and positioned to closely approximate or replicate the geometry and functional characteristics of a natural, healthy hip joint. Typically, the component selection process includes a pre-operative analysis of joint images. The component selection process also includes temporary fixation of one or more provisional components to a bone or bones of interest prior to permanent fixation of the prosthetic joint. The provisional components are intended to mimic certain aspects of the permanent prosthetic joint in order for a surgeon to validate measurements and to test or "tryout" several different component sizes and configurations. Hence, provisional components are aptly known as "trials."
In a known procedure, a trial for a hip femoral component is used in the following manner. The proximal end of a femur is resectioned and the medullary canal of the femur is reamed. A broach is inserted into the resectioned proximal end of the femur to provide a cavity within the bone dimensioned and contoured to receive a femoral stem. Prior to removing the broach, a trial neck or trunnion and trial head can be secured to the broach to simulate a complete femoral stem. Normally, several neck and head trials of varying lengths and geometries are successively joined to the broach in an attempt to determine an appropriate neck length and overall femoral stem length. Once these lengths have been determined, the trial neck and head are removed from the broach and the broach is removed from the femur. Subsequently, a femoral stem of the appropriate length is selected for insertion into the cavity defined by the broach using techniques known to those skilled in the art.
Two types of femoral prostheses are typically suitable for hip arthroplasty procedures. One type is a bipolar prosthesis. In general, a bipolar hip prosthesis includes a shell having an external surface which articulates with the acetabulum and an internal surface which articulates with the spherical head member of a prosthetic femoral component. The other type of prosthesis is often referred to as a unipolar endoprosthesis in which the prosthetic femoral component includes a spherical head member which is large enough to articulate directly with the acetabulum.
U.S. Pat. No. 5,156,626 describes a procedure used to implant a bipolar hip prosthesis utilizing a four piece trial reduction system. This system includes a femoral broach trial, a neck portion attached to the broach, a head trial attached to the neck, and a shell for receiving the head trial and fitting within the acetabulum of a patient. The trial procedure using these four pieces can be at times cumbersome for the physician because the head can tend to dislocate and move out of the shell when the physician is attempting to place the trial into position. In addition, the trial system requires the use of numerous parts that must be selected and mated in various combinations.
Unipolar trial systems used in implanting unipolar hips typically comprise a broach, neck, and head trial. Unipolar trial counterpart pieces could be used in some situations to perform the trial reduction of bipolar hip implants because one of the primary interests in performing a trial reduction in both bipolar and unipolar implant procedures is to determine device fit (i.e., shell or head) in the acetabulum. Also, in many cases, the range of motion of the bipolar implant can be approximated with a unipolar trial.
SUMMARY OF THE INVENTION
The present invention overcomes the disadvantages of known femoral trials by providing a bipolar to unipolar head trial adaptor that may be inserted into or removed from a bipolar shell to convert the bipolar shell trial into a unipolar head.
One embodiment of the adaptor further provides an adjustable neck that eliminates the necessity for multiple unipolar head trials corresponding to different neck lengths for each of the different possible head sizes. A preferred version of this embodiment provides a spring loaded snap-in adaptor and a quick release neck length adjusting mechanism.
The invention also provides a fixed length femoral head trial adaptor system. The fixed length trial adaptor includes a cylindrical barrel member having an internal cavity shaped to receive a neck trunnion from a femoral stem trial. The adaptor also includes a circumferential flange on the outer surface of the barrel having a resilient connecting element disposed thereon. The connecting element, which secures the adaptor to the shell trial, has a nominal first diameter which is compressible to a smaller second diameter in response to a force. When the compressive force is removed, the connecting element resumes its first diameter.
In a preferred embodiment, the connecting element is shaped so as to mate with an annular groove provided within the shell trial.
In a preferred embodiment, the circumferential flange is located at a predetermined position on the outer surface of the barrel member and the internal cavity has a predetermined depth so as to simulate a given neck trunnion length. In this manner, a plurality of adaptors, each representing different neck lengths, may be employed in a trial system.
DETAILED DESCRIPTION OF THE DRAWINGS
The invention will be more fully understood by reference to the following detailed description when considered in conjunction with the accompanying drawings, in which:
FIG. 1 is an exploded perspective view of a trial adaptor of the present invention having an adjustable neck length;
FIG. 2 is an exploded perspective view of the trial adaptor of the FIG. 1 rotated approximately ninety degrees;
FIG. 3 is a side view of the trial adaptor of FIG. 1;
FIG. 4 is a side view of a bipolar shell trial;
FIG. 4A is a cross-sectional view of the bipolar shell trial of FIG. 4;
FIG. 5 is a cross sectional view of the trial adaptor of FIG. 1 in use with a bipolar shell trial;
FIG. 6 is a cross-sectional view of a femoral trial system of the invention;
FIG. 7 is a top or superior view of a fixed length adaptor of the invention;
FIG. 8 is a cross-sectional view of the adaptor of FIG. 7 taken along line 8--8;
FIG. 9 is a an elevated view of a connecting element of the invention;
FIG. 10 is a cross-sectional view of the connecting element of FIG. 9 taken along line 10--10;
FIG. 11 is a cross-sectional view of a fixed length adaptor of the invention having a -3 mm offset;
FIG. 11A is a cross-sectional view of a fixed length adaptor of the invention having a 0 mm offset;
FIG. 11B is a cross-sectional view of a fixed length adaptor of the invention having a +5 mm offset; and
FIG. 11C is a cross-sectional view of a fixed length adaptor of the invention having a +10 mm offset.
DETAILED DESCRIPTION OF THE INVENTION
An adjustable trial adaptor 10 of the invention is illustrated in FIGS. 1-3. The adjustable trial adaptor 10 includes a cylindrical portion 11 having an opening 12 extending therethrough, spring loaded ball plungers 14 extending from the outer circumference 13 of the cylindrical portion 11 and a pawl 15 extending through the outer circumference 13 of the cylindrical portion 11 partially into opening 12.
The trial adaptor further includes a barrel 16 which acts as the adjustable neck portion of a unipolar head trial when the adaptor 10 is inserted into a bipolar shell. The barrel 16 comprises three grooves 17 in the outer circumference of the barrel 16. The barrel 16 further comprises a longitudinal slot 18 on the outer circumference 24 of the barrel 16, and openings 19 extending through the cylindrical wall 20 of the barrel. The barrel 16 comprises a longitudinal opening 21 extending from the bottom 26 of the barrel to a top wall 22 of the barrel. The top wall 22 includes a smaller opening 23 continuous with the opening 21.
A dowel pin 28 is press fit through the side of the cylindrical portion 11 and extends into capture slot 18 of barrel 16. The pin 28 movably secures the cylindrical portion 11 to the barrel 16 while the capture slot 18 permits the barrel 16 to move up and down between the three neck length positions defined by the grooves 17.
The pawl 15 comprises a button portion 40, a groove engaging portion 42, and a blind hole 46 for receiving compression spring 41. When assembled the pawl 15 is inserted into the opening 25 and is rotatably coupled to the cylindrical portion 11 with a dowel pin 47 press fit through hole 51 in cylindrical portion 11 and through hole 48 in pawl 15. The compression spring 41 is inserted into the hole 49 in the cylindrical portion 11 and into hole 46 in pawl, aligned with hole 49 of cylindrical portion 11. A dowel pin 50 extends into cylindrical portion 11 across hole 49 to capture the spring 41 in a compressed state in holes 46, 49. The pawl 15 is biased by spring 41 towards the barrel 16 so that when the barrel 16 is in a locked position, the groove engaging portion 42 extends into one of the grooves 17. The button portion 40 is exposed at the outer circumference 13 of the cylindrical portion 11 so that a user may actuate the button 40 to release the engaging portion 42 from engagement with the groove 17 and move the barrel 16 into a desired position.
A bipolar shell trial 60, shown in FIGS. 4 and 4A, and further shown mated to the adaptor 10 in FIG. 5, is spherically shaped with a flat inferior region 62.
An adaptor-receiving opening 64 is formed in the flat inferior region 62. A bone-contacting outer surface 66 of the shell trial 60 articulates with an acetabulum. The shell trial 60 is provided with a second, apical opening 67 which may be used to access the interior of the shell trial 60. Generally, the bipolar shell trial 60 is available in a variety of sizes having an outer diameter ranging from about 38 to 63 millimeters and a height ranging from about 27.5 to 40 millimeters.
The shell trial 60 also has an inner, non-bone contacting surface 65 that defines a cavity extending internally within the shell 60 from the opening 64. The inner surface 65 includes a hemispherical region 68 which may articulate with a head trial in a bipolar trial reduction that does not use an adaptor of the invention. Accordingly, a single shell trial component 60 may be used either in a bipolar trial, or with an adaptor of the invention as a head trial.
The inner surface 65 of shell trial 60 also defines an annular groove 70 and an annular shelf 72 which engage an adaptor, such as the trial adaptor 10, in concert to positively seat and retain the adaptor. The annular groove 70 is located internally to the adaptor receiving opening 64 and is shaped to accept a connecting element on a trial adaptor such as the spring loaded ball plungers 14 of trial adaptor 10. The annular shelf 72, also located within the opening 64, provides a positive seating means for the trial adaptor 10 with respect to the shell trial 60.
The shell trial 60 may be constructed from any material useful for temporary surgical use. Such materials include a variety of copolymers, particularly acetal copolymers, but also including polymeric material such as polyethylene, polypropylene, polyphenyl sulfone and nylon.
In use, as illustrated in FIG. 5, a trial adaptor 10 is inserted into the shell trial 60. The cylindrical portion 11 is inserted into the adaptor-receiving opening 64 in a bipolar shell trial 60 with the barrel 16 extending down from the adaptor 10. The top portion 27 of the cylindrical portion 11 abuts against shelf 72, and spring loaded ball plungers 14 fit into the groove 70 formed within the bipolar shell trial 60. Thus, the adaptor may be snapped into place within the bipolar shell trial 60 and held there by spring loaded ball plungers 14 that extend into groove 70.
As shown in FIG. 6, the barrel 16 acts as an interface for a femoral neck trunnion 76 of the femoral trial 74. The femoral neck trunnion 76 may be coupled to the adaptor 10 by inserting it into the opening 21 in the barrel 16.
As assembled, the barrel 16 is inserted into the opening 12 of the cylindrical portion 11. The grooves 17 serve to engage with the pawl 15 to lock the barrel 16 into a selected position corresponding to a desired neck length. Thus the adaptor is arranged to extend the neck length of the femoral trial. The three grooves 17 correspond to three different neck lengths, for example, to zero, five and ten millimeter neck lengths.
The button portion 40 of the pawl 15 is activated to release the engaging portion 42 from the groove 17 engaged by the pawl 15. The barrel 16 is extended to a position so that the neck portion 45 of the femoral trial 44 when attached to the barrel 16 will be at a desired length. The button portion 40 is then released causing the pawl 15 to engage the groove 17 adjacent the pawl 15, locking the barrel 16 into the desired position.
The adjustable neck feature may be incorporated into any trial system whether it be a unipolar, bipolar, etc. system. The adjustable neck may be included with an adaptor as described or with any head or neck portion of a trial system.
The unipolar adaptor 10 may be disassembled from the bipolar shell trial 30 by pushing through the shell trial's apical hole 67 with any small diameter cylindrical instrument at hand.
Alternatively, a fixed length trial adaptor 80, illustrated in FIGS. 7 through 11C, may be employed in place of the adjustable trial adaptor 10. The fixed length trial adaptor 80 includes a generally cylindrical barrel member 82 having an outer surface 84 and superior and inferior ends 86, 88. A circumferential flange portion 90 is integral with the outer surface 84 of the barrel member between the superior and inferior ends 86, 88. The flange portion 90 is generally cylindrical, is smaller in height than the barrel member 82 and extends radially outward from the outer surface 84 of barrel member 82 to an outer diameter D 2 .
The barrel member 82 has an inferior opening 94 and an inner surface 95 that defines a cavity 96 extending inwardly from the opening 94. The cavity 96 is adapted to seat a femoral neck trial. The internal cavity 96 is generally cylindrical and extends from the inferior opening 94 superiorly to an end region 98 against which a femoral neck trunnion abuts. The cavity 96 may be tapered so as to fit conventional neck trial trunnions which are also tapered. One of ordinary skill in the art will radily understand that various tapers can be used. Common tapers include 10/12 and 11/13 sizes in which the two numbers in each size designation represent the diameter of the neck measured at two different points along its length.
Grooves 100, 102 may be provided within the cavity 96 for seating one O-ring 104, 106 each. The O-rings 104, 106, which are preferably formed from a silicone rubber material, allow the adaptor 80 to mate snugly with a neck trial trunnion even where dimensions of the trunnion vary from a trial to a permanent prosthesis or among different manufacturers who may have different standards for measuring or sizing the tapers. In addition, the O-rings allow the mating between the neck and adaptor 80 to take place at two points along the length of the cavity 96. This configuration is preferable to direct mating along the length of the cavity 96 which can make it difficult to remove the trial adaptor 80 from the neck. As an alternative to O-rings, it is also possible to use at least one raised circumferential ridge (not shown) within the cavity 96 for the same purpose.
In a preferred embodiment, flange portion 90 has a groove 108 about its outer circumference suitable for seating a resilient connecting element 110. The connecting element 110, in an embodiment illustrated in FIGS. 9 and 10, is an arc member having an inner diameter 112 that exceeds the diameter D 1 the groove 108 so that, when the connecting element 110 is in an a first, unflexed position, a clearance 114 (shown in FIG. 8) exists between the groove 108 and the connecting element 110. The nominal (unflexed) outer diameter 116 of the connecting element 110 also exceeds the outer diameter D 2 of the flange portion 90, preferably by about 0.05 to 0.11 inch.
The connecting element 110 is made from a flexible material so that the arc may be compressed from a first, unflexed position to a second, compressed position wherein the connecting element 110 maintains a second outer diameter that is less than its nominal outer diameter 116 in response to a compressive force such as when the adaptor 80 is pressed into the shell trial 60. The exemplary connecting element 110 may be formed as a complete ring, but a portion corresponding to an angle α is preferably removed from the connecting element 110. The removed portion α may generally be an arc of between about 10° to 60°, and preferably is an arc of about 30°.
One of ordinary skill in the art will readily appreciate that the connecting element 110 may be made from a variety of resilient materials that possess shape memory. Such materials include polymeric materials as well as metallic materials. Exemplary materials include acetal copolymer, polyethylene, polypropylene, polyphenyl sulfone and nylon.
When the adaptor 80 is inserted into the shell 60, contact forces from the inner cavity 65 of the shell trial 60 compress the resilient connecting element 110 from its first, nominal outer diameter 116 to its second, compressed outer diameter and the adaptor 80 slides into the shell trial 60. When the flange portion 90 meets the annular shelf 72 within the shell trial opening 64, the connecting element 100 correspondingly becomes aligned with the annular groove 70 and the resilient connecting element 110 expands to mate with the groove 70 and thereby secures the adaptor 80 to the shell trial 60. The connecting element 110 preferably has a rounded outer edge 118 configured to correspond to the shape of the annular groove 70 to facilitate mating therewith.
The fixed length trial adaptor 80 may be removed from a shell trial by inserting an appropriate tool through the apical hole 67 in the shell trial as described with respect to the adjustable length adaptor 10. The adaptor 80 may further be provided with an oblong opening 120 on its superior end 86. A tool (not shown) having a cylindrical insertion member and a cross member proximate to its insertion end may be inserted through the oblong opening 120 from the inferior side with the cross-member aligned with the oblong hole 120. The tool may then be rotated 90° so that the cross member is no longer aligned with the oblong hole 120. The adaptor 80 can then be separated from the shell 60 by pulling on the tool with sufficient force to compress the resilient connecting element 110 and remove the adaptor 80.
Trials of various neck trunnions may be simulated using fixed length trial adaptors having different effective lengths. The effective length of the trial adaptor 80 may be varied, for example, by locating the circumferential flange portion 90 at different positions along the barrel member 82. The location of the end region 98 of the barrel's internal cavity 96 may also be varied to this effect. Fixed length trial adaptors 80 having relative effective lengths of -3 mm, 0 mm, +5 mm and +10 mm are illustrated in FIGS. 11, 11A, 11B and 11C, respectively.
A physician may elect during surgery to convert the bipolar shell trial into a unipolar head by inserting the adjustable length unipolar trial adaptor 10 or the fixed length unipolar trial adaptor 80 into shell 60. Use of either adaptor allows a physician to adjust the fit of the head or the bipolar shell and reduce the femur while electing the appropriate neck length without the usual cumbersome bipolar trial system.
The trial system preferably includes various bipolar shell sizes and various femoral stem sizes to allow the surgeon to select the appropriate size while performing a trial reduction. Where fixed length adaptors 80 are used, the trial system preferably includes a plurality of adaptors 80 representing different relative neck lengths.
Although the present invention is described with respect to particular embodiments and features and uses, numerous variations or equivalents are possible without taking away from the spirit or scope of the claimed invention. All references cited herein are expressly incorporated by reference in their entirety.
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A femoral head trial adaptor for converting a shell trial to a head trial includes a barrel member having an outer surface and an inner surface defining a cavity for receiving a femoral neck trial. A circumferential flange portion is located on the outer surface of the barrel member. A resilient connecting member disposed on the circumferential flange has a nominal first diameter compressible to a smaller second diameter in response to a force and returnable to the first diameter in the absence of the force for securing the trial adaptor to a shell trial. The flange may be located at a predetermined position along the outer surface of the barrel member so as to simulate a neck trial of a given length.
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BACKGROUND OF THE INVENTION
Many devices exist for use in grilling, roasting, and/or smoking poultry. These devices can be elaborate, as typified by motorized rotisseries that employ doneness probes, and can also be extremely simple. A popular and very simple method of preparing poultry on a grill is commonly known as “beer can chicken” where an open can of beer is placed on a hot grill, and the chicken is placed on the beer can such that the beer can is inserted into the hollow body cavity of the chicken and the chicken is maintained in an upright position. The heat from the grill causes the beer in the can to steam and boil, marinating the interior of the chicken and providing a cooked chicken that is flavorful and moist.
Though simple and effective, there are many drawbacks to cooking poultry over a beer can. For example, the beer can-and-chicken combination is unstable. When a beer can-and-chicken combination topples, the chicken can become soiled or contaminated, and the spilled beer may extinguish the fire within the grill. Secondly, a beer can comes in only one size so that this cooking method will not work will small poultry such as Cornish hens, or with very large poultry such as turkeys. Thirdly, the exterior surface of a beer can has coatings including paint and other finishes which may be toxic when heated. Finally, the chicken (or other poultry product) is not protected from the heat source in any way so that the drippings from the chicken fall directly onto the heat source, causing localized flame-ups which can burn the outside of the chicken.
A need exists for a simple device which will allow cooking of raw, eviscerated poultry by grilling, roasting, and/or smoking while providing stability during the cooking process, allowing steam or juices to be infused into the internal cavity of the poultry, and protecting the exterior of the poultry from. intense heat and flames during the cooking process. The device will adjust in size to allow cooking of a variety of sizes of poultry, and will collect the juices of the cooking poultry for re-infusion into the cooking bird.
A wide variety of devices are shown in the prior art. U.S. Pat. No. 6,125,739 that issued to Jernigan on Oct. 3, 2000 shows a device for supporting and steaming fowl consisting of a hollow, perforated, frustoconical insert mounted to a circular base, where the insert is filled with liquid for steaming the interior of the fowl during cooking. U.S. Pat. No. 6,119,585 that issued to Guidry on Sep. 19, 2000 discloses a cooking apparatus suitable for grilling whole chickens on a grill, the apparatus comprising a vertically oriented cylinder mounted to a base plate. The chicken resides upon the cylinder when the base plate is resting on a grill. The use of a flavored liquid within the cylinder to enhance the taste of the chicken is described, as is the use of perforations in the base to allow drippings from the cooked food to reach the heat source. However, these patents do not disclose a means for collection of juices from the cooking fowl, and do not provide a means to compensate for various sized poultry. The U.S. Pat. No. 532,729 to Glassmeyer that issued on Jan. 15, 1895 discloses a cooking apparatus having an automatic baster including a cooking pan and rack. The U.S. Pat. No. 495,821 that issued to Martin on Apr. 18, 1893 discloses a dripping pan with a perforated top member. However, these patents do not disclose a perforated tower on which to mount poultry during cooking and which will allow internal infusion of the poultry with steam and juices during cooking.
SUMMARY OF THE INVENTION
An innovative apparatus for cooking poultry is described herein that will allow cooking of raw, eviscerated poultry by grilling, roasting, and/or smoking, both in a conventional oven and using an outdoor cooker such a grill or smoker. The innovative apparatus will provide stability during cooking, allow flavored or unflavored steam and poultry juices to be infused into the internal cavity of the poultry, and protect the exterior of the poultry from direct heat and flames during the cooking process. The apparatus will adjust in size to allow cooking of a variety of sizes of poultry, and will collect the juices of the cooking poultry for re-infusion into the cooking bird.
The apparatus consists of a shallow pan and a lid that covers the pan. The lid contains a centrally located opening. The lid supports an upwardly extending, hollow, perforated poultry-supporting tower on its upper surface. The tower is mounted over the centrally located opening such that steam generated within the pan during cooking rises up into the tower, escapes through the perforations thereby infusing the poultry. The lid is also provided with at least one drain hole so that the drippings from the cooking poultry can be trapped within the pan, and re-infused into the poultry. This feature also promotes a cleaner grill, cooker, or oven since the drippings are captured within the apparatus.
The tower is detachable from the lid, and is interchangeable with alternative towers of differing lengths having different circumferences. Thus, a relatively short tower, that may have a small circumference is detachably affixed to the lid for use in cooking small poultry such as Cornish hens, and can be replaced with a mid-length tower having a medium circumference for use in cooking medium sized poultry such as chicken or duck, and can be replaced with a long tower having a large circumference for use in cooking large poultry such as turkey or geese.
In use, the appropriate tower for the poultry being cooked is secured to the lid and the raw, eviscerated poultry is placed on the apparatus such that the tower extends into the body cavity of the poultry and the poultry is supported in a vertical position. A preferred liquid is placed within the interior of the pan and the pan is covered with the lid. The apparatus is placed on a grill or in an oven or smoker. The heat source causes the poultry to cook from the exterior in the conventional manner with the result that drippings fall onto the lid where they drain into the pan. The heat source simultaneously causes the liquid within the pan, including the drippings, to convert to steam. The steam escapes from the interior of the pan through the perforations of the tower, thereby infusing steam into the body of the poultry from the inside. The liquid may be non-flavored and be used to provide moist, tender cooked meat. The liquid may also be flavored or seasoned, and may include beer or wine, or a marinade. Use of a flavored liquid imparts a desired flavor to the moist and tender cooked meat.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the preferred embodiment of the poultry cooking apparatus, illustrating the pan covered by the lid, the tower mounted to an upper surface of the lid, the tower having perforations about its side walls and a closed upper end.
FIG. 2 is a top view of the poultry cooking apparatus, illustrating the central positioning of the tower on the lid, and drain holes between the tower and the periphery of the lid.
FIG. 3 is a perspective view of cylindrically shaped interchangeable towers, illustrating a Cornish hen sized tower ( 3 A), a chicken sized tower ( 3 B), and a turkey sized tower ( 3 C).
FIG. 4 is a side sectional view of the poultry cooking apparatus in use, illustrating a poultry mounted on a cylindrical tower, the tower residing within the internal body cavity of the poultry such that when the liquid within the pan boils, steam infuses the body of the poultry.
FIG. 5 is a side sectional view of the poultry cooking apparatus where a second embodiment of the tower is employed, illustrating a tower in the shape of a frustum.
DETAILED DESCRIPTION OF THE INVENTION
The innovative poultry cooking device 10 will now be described with respect to the figures. Poultry cooking device 10 has three components. They are a pan 20 , a removable lid 40 , and a tower 60 for supporting poultry 5 in a vertical orientation above pan 20 and lid 40 .
Pan 20 is has closed bottom 24 surrounded by side wall 22 . Pan 20 is shallow such that the height of side wall 22 is much less than the diameter of bottom 24 . In the preferred embodiment, pan 20 is generally cylindrical so that the peripheral edge 30 of bottom 24 is formed in the shape of a circle, with side wall 22 completely surrounding peripheral edge 30 . Side wall 22 extends upwardly from bottom 24 such that lower edge of side wall 22 is integral with bottom 24 . Side wall 22 may be normal to bottom 24 (FIG. 5 ), or may be angled slightly so that upper edge 26 of side wall 22 has a greater diameter than lower edge 28 of side wall 22 (FIGS. 1 and 4 ). It well within the scope of this invention, however, to form pan 20 with peripheral edge 30 of bottom 24 formed in a shape which includes, but is not limited to, a square or other polygonal shape.
Lid 40 is a generally flat plate having an upper surface 42 and a lower surface 44 . Lid 40 has a peripheral edge 48 having the same shape as peripheral edge 30 of bottom 24 . In use, peripheral edge 48 of lid 40 rests on upper edge 26 of side walls 22 such that lower surface 44 of lid 40 abuts and confronts side walls 22 and is removable therefrom. Peripheral edge 48 surrounds body portion 49 of lid 40 . Lid 40 has a central opening 46 that is centered within body portion 49 .
Flange or sleeve 52 surrounds central opening 46 and extends upwardly from upper face 42 . Flange 52 is sized and shaped to receive tower 60 therein. In the preferred embodiment, central opening 46 is circular in shape so that flange 52 forms a short ring about this opening. It is well within the scope of this invention to provide central opening in alternative shapes to accommodate the shape of the periphery of tower 60 . In the preferred embodiment, flange 52 is welded to lid 40 , but may be secured to lid 40 by any conventional means or may be formed integrally with lid 40 .
Flange 52 is provided with at least one, but preferably two, holes 57 through it. Holes 57 are located on opposing sides of flange 52 such they are horizontally aligned, and are sized and shaped to receive a pin 58 therein. Pin 58 is provided in a length that is greater than the diameter of flange 52 such that pin 58 can extend through both holes 57 simultaneously.
In the preferred embodiment, lid 40 is slightly convex such that peripheral edge 48 lies in a first plane, and body portion 49 lies in a second plane that lies below the first plane when lid 40 is resting on pan 20 . Peripheral edge 48 may either be flat such that it lies in the horizontal plane (FIG. 5 ), or it may be folded downward so as to form a groove 47 in which to receive the upper edge 26 of side wall 22 (FIG. 4 ). The convexity of lid 40 prevents drippings from the cooking poultry from running off lid 40 over peripheral edge 48 , and allows the drippings to be gathered in body portion 49 . Body portion 49 is provided with at least 1 , but preferably a plurality of small drain holes 50 which allow the drippings to be received within the internal space of pan 20 . Drain holes 50 are much smaller in diameter than central opening 46 , and provide the added benefit of allowing a small amount of steam to escape from body portion 49 , thereby adding moisture and flavor to the exterior surface of the cooking poultry 5 .
Tower 60 is an elongate hollow member having a closed first or upper end 62 , an open second or lower end 64 , and a mid portion 66 extending between upper end 62 and lower end 64 . Upper end 62 is closed so that steam rising within tower 60 is directed horizontally toward the interior of the poultry, rather than escaping upwardly to no effect. Lower end 64 is open, and in use resides over the central opening 46 of lid 40 , allowing steam to rise into the mid portion 66 of tower 60 . Tower 60 has an inner surface 70 , and an outer surface 72 which is opposed to inner surface 70 and which confronts the interior surfaces of poultry 5 .
The outer diameter of tower 60 is sized to be received within flange 52 such that outer surface 72 of tower 60 confronts and abuts the inner surface 54 of flange 52 . Mid portion 66 adjacent to second end 64 is provided with at least one, but preferably two, holes 74 therethrough. Holes 74 are located on opposing sides of tower 60 such they are horizontally aligned, and are sized and shaped to receive pin 58 therein.
Tower 60 is secured to flange 52 by alignment of flange holes 57 with tower holes 74 , and simultaneous placement of pin 58 within each respective hole pair 57 , 74 . Pin 58 provides a means of releasably securing tower 60 to flange 52 so that in use tower 60 may be removed from lid 40 to be interchanged with a shorter tower 60 ′ or longer tower 60 ″ as appropriate for the size of poultry to be cooked.
Mid portion 66 of tower 60 is provided with a plurality of holes 68 therethrough. The holes 68 provide a means whereby steam 8 generated from liquid 7 within pan 20 may flow outward from the hollow interior of tower 60 and into the interior cavity of poultry 5 . The holes 68 may be randomly positioned on mid portion 66 , or placed thereon in a regular pattern so long as they provide sufficient steam flow in all portions of tower 60 .
In the preferred embodiment, tower 60 is cylindrical in shape (FIGS. 1 - 4 ). It is well within the scope of this invention, however, to form tower 60 in alternative elongate hollow shapes. FIG. 5 illustrates the second embodiment tower 600 formed in the shape of a frustum.
Tower 600 is provided with member having a closed first or upper end 620 , an open second or lower end 640 , and a mid portion 660 extending between upper end 620 and lower end 640 . Upper end 620 of second embodiment tower 600 is of smaller diameter than lower end 640 , providing a frustoconical shape that may more closely approximate the shape of the interior cavity of poultry 5 . As in the preferred embodiment, upper end 620 is closed so that steam rising within tower 600 is directed horizontally toward the interior of the poultry, rather than escaping upwardly to no effect. Lower end 640 is open, and in use resides over the central opening 46 of lid 40 , allowing steam to rise into the mid portion 660 of tower 600 . Tower 600 has an inner surface 700 , and an outer surface 720 which is opposed to inner surface 700 and which confronts the interior surfaces of poultry 5 .
The outer diameter of tower 600 is sized to be received within flange 52 such that outer surface 720 of tower 600 confronts and abuts the inner surface 54 of flange 52 . Mid portion 660 adjacent to second end 640 is provided with at least one, but preferably two, holes 740 . The holes 740 are located on opposing sides of tower 600 such they are horizontally aligned, and are sized and shaped to receive pin 58 therein.
Tower 600 is secured to flange 52 by alignment of flange holes 57 with tower holes 740 , and simultaneous placement of pin 58 within each respective hole pair 57 , 740 . Pin 58 provides a means of releasably securing tower 600 to flange 52 so that in use tower 600 may be removed from lid 40 to be interchanged with a shorter tower 600 ′ (not shown) or longer tower 600 ″ (not shown) as appropriate for the size of poultry to be cooked.
Mid portion 660 of tower 600 is provided with a plurality of holes 680 . Holes 680 provide a means whereby steam 8 may flow outward from the hollow interior of tower 600 and into the interior cavity of poultry 5 . Holes 680 may be randomly positioned on mid portion 660 , or placed thereon in a regular pattern so long as they provide sufficient steam flow in all portions of tower 600 .
In the preferred embodiment pan 60 and lid 40 are provided having diameters in the range of 9 to 12 inches, where a 9 inch diameter poultry cooking device 10 is suitable for cooking a chicken, and a 12 inch diameter poultry cooking device is suitable for cooking a turkey. Side walls 22 of pan 60 have an approximate height of 2 inches, and flange 52 has an approximate height of 1 inch. Tower 60 has an approximate outer diameter of 1 inch. The preferred length of tower 60 is approximately 8 inches, and may be provided in various lengths in the range of 5 to 12 inches to accommodate various poultry types and sizes.
Poultry cooking device 10 is preferably formed of a metal, preferably aluminum, because of its excellent heat transfer properties and tolerance of high temperatures. However, it is within the scope of this invention to use alternative materials that would be adequate for the purposes described, or to modify the metal by providing non-stick coatings or other improvements while maintaining the spirit of the inventive concept.
While I have shown and described the preferred embodiment of my invention, it will be understood that the invention may be embodied otherwise than as herein specifically illustrated and described, and that certain changes in the form and arrangements of parts and the specific manner of practicing the invention may be made within the underlying idea or principles of the invention within the scope of the appended claims.
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An apparatus for cooking poultry consists of a shallow pan, and a lid which covers the pan and which is provided with a centrally located opening. The lid supports an upwardly extending, hollow, perforated poultry-supporting tower on its upper surface. The detachable tower is mounted over the centrally located opening such that steam generated within the pan during cooking rises up into the tower, escapes through the perforations thereby infusing the poultry. The lid is also provided with at least one drain hole so that the drippings from the cooking poultry can be trapped within the pan, and re-infused into the poultry. The tower is detachable from the lid, and is interchangeable with alternative towers of differing lengths and circumferences to accommodate various sizes of poultry.
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BACKGROUND OF THE INVENTION
2-(2-Imidazolin-2-yl)pyridines and quinolines and their use as herbicidal agents are described in U.S. Pat. Nos. 4,638,068 issued Jan. 20, 1987 and 4,798,619 issued Jan. 17, 1989. These patents describe processes for the preparation of compounds having the structure: ##STR1## wherein A, B, R 1 , R 2 , W, X, Y and Z represent a wide variety of substituents and demonstrate pre-emergence and post-emergence herbicidal activity for more than three hundred of such imidazolinone pyridines and quinolines. The patents specifically disclose the compound 2-(4-isopropyl-4-methyl-5-oxo-2-imidazolin-2-yl)-5-methylnicotinic acid and demonstrate the herbicidal activity thereof against a variety of weed species. U.S. Pat. Nos. 4,638,068 and 4,798,619 do not disclose or suggest that 2-(2-imidazolin-2-yl)pyridines and quinolines are active against leguminous weed species (e.g. Cassia obtusifolia L. or Cassia nictitans, L.) either alone or in the presence of a leguminous crop.
SUMMARY OF THE INVENTION
This invention relates to a method for the selective control of leguminous weeds in the presence of leguminous crops comprising applying to the foliage and stems of said leguminous weeds herbicidally effective amount of 2-(4-isopropyl-4-methyl-5-oxo-2-imidazolin-2-yl)-5-methylnicotinic acid.
Surprisingly, it has now been discovered that one imidazolinone out of the three hundred or more imidazolinones disclosed in U.S. Pat. Nos. 4,638,068 and 4,798,619; namely the compound: 2-(4-isopropyl-4-methyl-5-oxo-2-imidazolin-2-yl)-5-methylnicotinic acid, is unique in its ability to selectively control leguminous weed species in the presence of certain leguminous bean crops. More particularly, it has been found that the compound 2-(4-isopropyl-4-methyl-5-oxo-2-imidazolin-2-yl)-5-methylnicotinic acid can be applied as a post emergent herbicidal agent to established sicklepod (Cassia obtusifolia L.) plants growing in the presence of soybeans (Glycine max) to control the sicklepod without producing significant injury to the soybeans. This unique selective herbicidal activity of the above-said compound allows control of bean family weed species in the presence of crop plants of the bean family, without significantly injurying said crop plants. Moreover, this unusual activity establishes the compound 2-(4-isopropyl-4-methyl-5-oxo-2-imidazolin-2-yl)-5-methylnicotinic acid as unique amongst imidazolinones.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In one embodiment, the present invention provides a method for controlling sicklepod in the presence of soybeans by applying to said sicklepod when it is in at least the second true leaf stage of growth, about 0.057 kg/ha to about 0.22 kg/ha of 2-(4-isopropyl-4-methyl-5-oxo-2-imidazolin-2-yl)-5-methyl-nicotinic acid. When the sicklepod and the soybeans are well established and both are about 30 to 45 centimeters in height, the application to said plants of about 0.56 kg/ha to about 1.12 kg/ha and preferably about 0.75 kg/ha to about 1.12 kg/ha of 2-(4-isopropyl-4-methyl-5-oxo-2-imidazolin-2-yl)-5-methylnicotinic acid is effective for reducing and/or eliminating the stand of sicklepod without significantly injuring the soybean crop.
For use in method of the present invention 2-(4-isopropyl-4-methyl-5-oxo-2-imidazolin-2-yl)-5-methyl-nicotinic acid is usually prepared as aqueous urea solution comprising about 15% to 25% by weight of 2-(4-isopropyl-4-methyl-5-oxo-2-imidazolin-2-yl)-5-methyl-nicotinic acid; about 0.05% to 1.0% by weight of acetic acid; about 3.0% to 7.0% ammonium hydroxide, aqueous (NH 3 29%); about 15% to 25% by weight of urea and q.s. to 100% with water, which is usually about 45% to 60% by weight of water. Silicone antifoam agent may also be included in the formulation in a concentration of from 0 to about 0.2%.
A typical 2 pound per gallon aqueous solution of the above-identified imidazolinone may have the following compositions:
______________________________________Component W/W %______________________________________2-(4-isopropyl-4-methyl-5- 23.7oxo-2-imidazolin-2-yl)-5-methylnicotinic acid(95% purity)Aqueous ammonium hydroxide 5.7Urea 15.0Water 54.8Acetic acid 0.730% silicone emulsion 0.1antifoamTotal 100.0%______________________________________
In the field the above-identified formulation, which is a 2 pound per gallon 2-(4-isopropyl-4-methyl-5-oxo-2-imidazolin-2-yl)-5-methylnicotinic aqueous solution with urea, is usually diluted with a sufficient amount of water to yield the desired concentrate of the active ingredient in the aqueous spray. A surface active agent may be added to the diluted formulation for spray application. The surfactant if added is usually employed at a concentration between about 0.20% and 0.30% by weight of the finished dilute formulation.
Among the nonionic surfactants that can be used in the diluted formulations of this invention are octylphenoxy polyethoxy ethanol, alkylaryl polyether alcohols, alkylaryl polyoxyethylene glycol, nonylphenoxy polyethoxy ethanol and the like.
Typically the 2-(4-isopropyl-4-methyl-5-oxo-2-imidazolin-2-yl)-5-methylnicotinic acid or its aqueous ammonium salt is employed, but other salts or esters of the acid may be used in accordance with the present invention.
The invention is further illustrated by the following non-limiting examples.
EXAMPLE 1
Preparation of 2-(4-isopropyl-4-methyl-5-oxo-2-imidazolin-2-yl)-5-methylnicotinic acid aqueous solution with urea
This formulation is prepared by introducing about 49.32 parts by weight of the water into a kettle and dissolving therein 5.7 parts by weight of aqueous ammonium hydroxide and 15 parts by weight of urea. The mixture is stirred and 0.1 part by weight of silicone antifoam agent is dispersed therein. The pH of the mixture is then adjusted with acetic acid, preferably glacial acetic acid, to between 6.5 and 8.0, preferably about 7.2 and 5.48 parts by weight of water added to provide the 2 pound per gallon imidazolinone aqueous solution with urea.
EXAMPLE 2
Evaluation of 2-(4-isopropyl-4-methyl-5-oxo-2-imidazolin-2-yl)-5-methylnicotinic acid for control of Sicklepod (Cassia obtusifolia L.) in the presence of soybeans (Glycine max (L) Merr)
In this evaluation the 2 pound per gallon aqueous solution of the imidazolinone with urea described in Example 1 is dissolved in tap water in sufficient amount to provide from 0.057 kg/ha to 0.22 kg/ha of said imidazolinone when the dilute aqueous solutions are applied as liquid sprays to fieldgrown sicklepod in the presence of soybeans at the rate of about 188 liters per hectare. The sicklepod and the soybeans are at the second true leaf stage of growth at the time of spraying. A CO 2 back pack sprayer is used and 0.25% by weight of a nonionic octylphenoxy polyethoxy ethanol is added to the diluted formulations in the tank. The plots are randomly selected and sprayed with the selected solution for evaluation. Each plot is approximately 4 meters wide and 30 meters long with soybeans planted in rows on 91 cm centers. The sprayed plots are examined at intervals throughout the growing season and evaluated 3 weeks after treatment using a rating system of 7 to 100%; 0%=no weed control, 100%=complete weed control. Data for sicklepod control and soybean retardation are reported below for the treatment rates used. After rating, the plants are permitted to grow to yield and the various treatments are reported below in Tables I and IA.
TABLE I______________________________________Evaluation of 2-(4-isopropyl-4-methyl-5-oxo-2-imidazolin-2-yl)-5-methylnicotinicacid for control of sicklepod in thepresence of soybeans % % Retar- Rate Control of dation ofActive Ingredient kg/ha Sicklepod Soybeans______________________________________2-(4-isopropyl-4- 0.22 90 20methyl-5-oxo-2-imidazolin-2-yl)- 0.11 80 205-methylnicotinicacid 0.057 75 20Unteated control 0.0 0 0______________________________________
TABLE I-A______________________________________ Rate Soybean YieldActive Ingredient kg/ha kg/ha______________________________________2-(4-isopropyl-4- 0.22 42.3methyl-5-oxo-2-imidazolin-2-yl)- 0.11 39.75-methylnicotinicacid 0.057 40.9Untreated control 0.0 32.3______________________________________
EXAMPLE 3
Evaluation of 2-(4-isopropyl-4-methyl-5-oxo-2-imidazolin-2-yl)-5-methylnicotinic acid for controlling well established sicklepod (30 centimeters to 45 centimeters in height) in the presence of soybean plants of essentially the same size and maturity.
In these tests, soybean plants approximately 30 to 45 centimeters in height, growing in rows approximately 30 meters in length and on 91 centimeter centers and very heavily infested between rows with mature sicklepod approximately 30 to 45 centimeters in height, are sprayed with aqueous solutions of 2-(4-isopropyl-4-methyl-5-oxo-2-imidazolin-2-yl)-5-methylnicotinic acid prepared as described in Example 1 above and diluted with a sufficient quantity of water to provide from 0.84 kg/ha to 1.12 kg/ha of the above-said imidazolinone when the dilute solutions are applied at the rate of 195 liters per hectare. Seventeen days after treatment the plots are examined and essentially 100% control of the sicklepod is observed with little or no injury to the soybeans.
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There is provided a method for the control of sicklepod (Cassia obtusifolia L.) in the presence of leguminous crops. More particularly, this invention provides a method for the selective control of sicklepod in the presence of bean plants by applying to the foliage of said sicklepod a herbicidally effective amount of 2-(4-isopropyl-4-methyl-5-oxo-2-imidazolin-2-yl)-5-methylnicotinic acid.
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This application is a continuation-in-part of U.S. Ser. No. 479,126, filed Mar. 28, 1983, and now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to analytical determinations of peroxidatively active substances in test samples, and particularly to a composition, test means, device and method useful in such determinations and resistant to possible adverse effects from ascorbic acid which may also be present in the sample.
2. Background Art
Many analytical methods are presently available for detecting the presence of peroxidatively active substances in biological samples such as urine, fecal suspensions, and gastrointestinal contents. For example, hemoglobin and its derivatives, the analytes determined by conventional occult blood tests, are typical of peroxidatively active substances because they behave in a manner similar to the enzyme peroxidase; as such, they are also referred to as pseudoperoxidases. Peroxidatively active substances are enzyme-like by virtue of their catalysis of the redox reaction between peroxides or hydroperoxides and such indicator compounds as benzidine, o-tolidine, 3,3',5,5'-tetramethylbenzidine, 2,7-diaminofluorene and the like, producing a detectable response such as a color change. Hence, most methods for determining the presence of occult blood in test samples rely on this pseudoperoxidase activity.
A number of analytical methods for determining peroxidatively active substances have evolved which rely on the enzyme-like catalysis of the peroxidative oxidation of colorforming indicators. Primarily, these include wet chemistry or solution procedures and the so-called "dip-and-read" type, reagent-bearing strip devices. Of the former, a typical example is set forth in R. M. Henry, et al., Clinical Chemistry Principles and Techniques, 2nd ed., 1124-1125 (Hagerstown, Md.: Harper and Row, 1974). This exemplary procedure involves the use of glacial acetic acid (buffer), diphenylamine (indicator) and hydrogen peroxide. While such wet chemistry methods have proven analytical utility, they possess many disadvantages, two examples of which are poor reagent stability and inadequate sensitivity.
Another method for the determination of peroxidatively active substances, and one presently preferred by most clinical analysts, utilizes the so-called "dip-and-read" reagent strip device. Typical of such "dip-and-read" devices is one commercially available from the Ames Division of Miles Laboratories, Inc. under the trademark HEMASTIX®. This device comprises a porous paper matrix impregnated with a buffered mixture of an organic hydroperoxide and an indicator, affixed to a plastic strip or handle. Upon immersion of the matrix in a liquid containing hemoglobin, myoglobin, erythrocytes or other peroxidatively active substances, i.e., pseudoperoxidases, a blue color develops in the matrix, the intensity of which is proportional to the concentration of the substance in the sample. By comparing the color developed in the matrix to a standard color chart, the analyst can determine, on a semiquantitative basis, the amount of analyte present in the sample.
Primarily, the advantages of such reagent strips over wet chemistry methods are: (1) the strip format is easier to use, requiring neither the preparation of reagents nor attendant apparatus; and (2) greater stability of reagents is afforded in the strip, resulting in improved accuracy, sensitivity and economy.
Whether a particular analysis for a peroxidatively active species is undertaken by either of the aforedescribed methods, a problem inherent to both exists: interference caused by the presence in the sample of reducing agents in general and ascorbic acid or ascorbate ion in particular (hereafter referred to as ascorbate interference). In the case of urinalysis for example, the recent popularity of diets which include high dosages of vitamin C (ascorbic acid) has resulted in serious ascorbate interference problems in analyzing for certain urine constituents, such as occult blood. Patients on such diets typically exhibit elevated levels of urinary ascorbate.
As early as 1938, the adverse effects of reducing agents such as ascorbate were recognized. R. Kohn and R. M. Watrous, Journal of Biological Chemistry, 124, 163-168 (1938). The same problem still plagues this area of diagnostic analysis, as evidenced by a proposal of 1979 that when an occult blood (a pseudoperoxidase) analysis is performed a simultaneous ascorbate analysis should also be performed in order to gauge the accuracy of the occult blood determination. L. Nielsen, P. J. Jorgensen and A. C. Hansen, Ugeskrift for Laeger, 141, 791-793 (1979).
Many attempts at removing ascorbate interference with test systems, such as systems containing glucose-sensitive reagents, are reported in the literature. With regard to glucose-sensitive assays, approaches have ranged from filtering out ascorbate before it reaches the reagents, to the utilization of an enzyme to decompose it, in situ.
Accordingly, Canadian Pat. No. 844,564 to Dahlqvist discloses a device for glucose determination in urine or other media which includes, in addition to a porous portion impregnated with normal glucose-responsive reagents, an additional portion to receive the urine test sample. The sample-receiving portion comprises an ion exchange material, whose singular function in the device is to adsorb any ascorbate present in the urine sample.
U.S. Pat. No. 4,168,205 to Danninger et al., suggests incorporating the enzyme ascorbate oxidase into the test reagent formulation; any ascorbate present in the sample will be enzymatically oxidized by the ascorbate oxidase to dehydroascorbate, a compound which does not adversely affect the desired analysis.
Another approach to alleviating ascorbate interference is reflected in Japanese Provisional Patent Publication No. 55757/1983 to Fuji Zoki Seiyaku K.K. The publication discloses the use of metal chelates of various ligands such as ethylenediaminetetracetic acid and diethylenetriaminepentacetic acid to pretreat a sample which will then be assayed for cholesterol, glucose or other components such as uric acid.
U.S. Pat. No. 3,411,887 to Ku describes the elimination of ascorbate interference with reagent systems which rely on enzymatic oxidizing substances such as glucose oxidase, by using an ascorbate "trapping system". The "trapping system" involves an ionizable heavy metal compound which when ionized has an oxidation-reduction potential falling between a redox indicator dye and ascorbate. Some suitable metals which are cited as examples include cobalt, iron, mercury and nickel.
U.S. Pat. No. 4,288,541 to Magers et al., commonly assigned herewith, describes the use of mercuric ion complexes, such as mercuric sarcosinate, to impart ascorbate resistance to a glucose/glucose oxidase assay system.
In addition to the foregoing, attention to the ascorbate problem with glucose tests is manifested by:
1. H. Gifford, et al., J. Amer. Med. Assoc., 178, 149-150 (1961).
2. P. O'Gorman, et al., Brit. Med. J., 603-606 (1960).
3. R. Brandt, et al., Clin. Chem. Acta, 51, 103-104 (1974).
4. R. Brandt, et al., Am. J. Clin. Pathol., 68, 592-594 (1977).
Similar to the approach of the above-cited Ku patent, other literature deals with the complexing and oxidation of ascorbate using cobalt. For example, G. Bragagnolo, Ann. Chim. Applicata, 31, 350-368, 1941, reported that solutions of ascorbic acid were oxidized by air in the presence of cobalt metal. Also, similar activity has been reported for Co(NH 3 ) 6 Cl 3 by Tomokichi Iwasaki in Journal of the Chemical Society of Japan, 63, 820-826 (1942).
Although the foregoing art deals extensively with analytical systems for glucose determinations, no suggestions are set forth as to resolution of the ascorbate interference problem in connection with the determination of such peroxidatively active substances as peroxidase and pseudoperoxidases such as occult blood (hemoglobin). Notwithstanding the disclosure of the Ku patent, supra, the aforementioned art indicates that metal ions, such as Co(III), are, in fact, also pseudoperoxidases. For example, Co(III) acetate is used commercially to catalytically decompose cumene hydroperoxide. [The Merck Index, 9th ed., 311 (1976).] A series of Co(III) complexes are reported to catalytically decompose peroxides by K. Lohs., Monatsber. Deut. Akad. Wiss. Berlin, 8, 657-659 (1966) (See Chem. Abstracts, 67, 120383z. 1967). One skilled in the art would clearly, therefore, be led to believe that the use of any such metal complexes in a typical analytical formulation for the determination of peroxidatively active substances, i.e., one containing an organic hydroperoxide and an indicator, would cause deleterious interaction with the hydroperoxide, either producing "false positive" results, or otherwise rendering it unreactive to the peroxidatively active substance of interest, such as occult blood, and thus useless for such determinations. In fact, efforts to use mercuric complexes, such as mercuric sarcosinate, in occult blood tests failed.
U.S. Pat. No. 4,310,626 to Burkhardt et al., commonly assigned herewith, addresses the foregoing problem in describing the use of ammonium Co(III) complexes for abating ascorbate interference with compositions for determining peroxidatively active substances. This patent discloses such compositions which comprise an organic hydroperoxide and a suitable indicator, such as 3,3'5,5'-tetramethylbenzidine, together with ammonium Co(III) complexes such as Co(NH 3 ) 6 Cl 3 , among others. These complexes, however did not impart sufficient ascorbate-resistance to an occult blood test to be commercially advantageous.
Other approaches to dealing with ascorbate interference in analytical determinations of peroxidatively active substances include, for example, West German Pat. No. 29 07 628. This German patent involves urinalysis in solution, whereby a urine sample is pretreated with one or more oxidants to remove ascorbate, and then contacted by the appropriate analytical reagents. The oxidants disclosed are sodium iodate, sodium periodate, calcium hydrochlorite, potassium triiodide, sodium hydrochlorite, chloroamine and bromosuccinimide.
In summary, various approaches to alleviating the interference problem presented by ascorbic acid in determinaton of peroxidatively active substances have included such techniques as the use of various Co(III) ammonium complexes, pretreatment of the sample with oxidizing agents and direct addition to the reagent composition of alkali metal iodates.
Pseudoperoxidases such as hemoglobin are often studied as alternate peroxidase systems in order to learn more about the mechanism of action of natural peroxidases such as those obtained from horseradish or potatoe sources. Ascorbic acid has long been known as a classical substrate for peroxidase, and ascorbic acid oxidation in the presence of metal chelates which act as pseudoperoxidases is a known phenomenon. In 1967 and 1968, M. Khan and A. Martell reported on kinetic studies of ascorbic acid oxidation in the presence of several ferric and cupric chelates over a pH range of 1.8 to 3.45. [Khan, M. and Martell, A., J. Am. Chem. Soc., 89, 4176 (1967); J. Am. Chem. Soc., 89, 7104 (1967); J. Am. Chem. Soc., 90, 3386 (1968).] A variety of kinetic and thermodynamic parameters were investigated in these studies. The result was a rank order of effectiveness of different chelates according to their abilities to oxidize ascorbic acid. Of four aminopolycarboxylic acids studied by these writers, the N-(2-hydroxyethyl)ethylenediaminetriacetic acid (HEDTA) chelate of Fe ++ was found to be the fastest oxidant. Both the work of Martell, and an earlier study by Grinstead, regard this ascorbic acid oxidation activity to constitute a "model" peroxidase system. [Grinstead, R. R., J. Am. Chem. Soc., 82, 3464 (1960).] Such studies as the foregoing by Grinstead constituted an attempt to study the peroxidase mechanism by means of a certain ferric chelate whose structure could mimic that of the iron-containing heme found at the active site of the enzyme peroxidase. Indeed, the writers use the phrase "model peroxidase system" repeatedly in their papers. However, because of the "model" peroxidase activity shown by this chelate and others which are similar in reactivity, one would certainly not expect that such substances could be incorporated into organic hydroperoxide/indicator systems such as those now typically used in analytical reagent compositions and devices for the determination of peroxidase or other peroxidatively active substances. Moreover, research studies undertaken by the assignee of the present invention in connection with peroxidase activity revealed that, with indicators such as 3,3',5,5'-tetramethylbenzidine (TMB) or o-tolidine (indicators which are typically used in analytical systems to determine the presence of peroxidatively active substances), such activity could be expected to occur some 200 times faster than with ascorbic acid. White-Stevens, R. H., Clin. Chem., 28, 578 (1982). Accordingly, it can be assumed that if such peroxidatively active metal chelates, "model" peroxidases, act to so readily oxidize ascorbic acid--an assumption made by Khan, Martell and Grinstead--then the peroxidase reaction with such indicators as TMB would proceed at least at the same rate as with ascorbic acid, if not some 200 times faster (as suggested in these latter studies, which were undertaken on horseradish peroxidase). Clearly, if an extremely reactive analyte is incorporated into the very reagent formulation designed to change color in the presence of that analyte, it is to be expected that "false positive" results would be obtained.
SUMMARY OF THE INVENTION
The foregoing teachings and suggestions notwithstanding, it has now been discovered that certain peroxidatively active metal chelates, and in particular certain metal chelates of polycarboxyalkylamines, when used in the manner of the invention as described herein, not only fail to produce expected "false positive" results in a composition comprising a system of reagents for determining peroxidatively active substances, but actually are unexpectedly advantageous in such systems in terms of reliability, stability, and sensitivity of the system to an analyte being determined. Moreover, it has been found that use of the metal chelates according to the present invention is particularly advantageous in overcoming the inaccuracies which can be caused by interference from ascorbate ion present in a test sample.
Accordingly, the present invention is based upon this discovery, and as stated supra, relates generally to analytical determinations of peroxidatively active substances which are resistant to ascorbate interference, and particularly to ones which according to the instant invention utilize a composition comprising an organic hydroperoxide and a redox indicator, for example, o-tolidine or 3,3',5,5'-tetramethylbenzidine, as well as a peroxidatively active metal chelate. In such determinations, the peroxidatively active analyte, because it mimics the enzyme peroxidase, catalyzes or otherwise participates in a reaction between the indicator and the organic hydroperoxide. The reaction yields a color or other detectable response, the intensity of which is indicative of the concentration of the analyte. Ascorbate ion, when present, causes a serious interference problem. The presence of a peroxidatively active metal chelate in the composition would also be expected to interfere with the analytical determination of a peroxidatively active analyte. Nevertheless, it has been discovered that novel compositions, test means (and devices), resistant to the interfering effects of ascorbic acid in a sample, can be successfully formulated for detecting the presence of a peroxidatively active substance in the sample; which compositions, test means (and devices) include metal chelates of polycarboxyalkylamine derivatives known also as "model peroxidases".
Accordingly, the composition of the invention comprises an organic hydroperoxide, an indicator capable of providing a detectable response, such as a color change, in the presence of the peroxidatively active substance and peroxide, and, additionally, a metal chelate which is a polycarboxyalkylamine derivative having the general formula ##STR2## where R 1 is hydrogen or straight or branched chain alkyl alcohol or alkyl carboxylic acid radicals having from 2 to 3 carbon atoms; R 2 , R 3 , R x and R y , same or different, are straight or branched chain alkyl alcohol or alkyl carboxylic acid radicals having from 2 to 3 carbon atoms; where at least two of R 1 , R 2 , R 3 , R x or R y are alkyl carboxylic acid radicals so defined; R p and R q , same or different, are straight or branched chain alkylene radicals having from 1 to 3 carbon atoms or divalent 1,2-cycloaliphatic radicals having from 6 to 9 carbon atoms; n is an integer having a value of from 0 to 1; m is an integer having a value of from 0 to 2; and M is Fe +3 .
Preferred compounds are those for which m is 0; n is 0 or 1 and R p is an ethylene radical. Particularly preferred are the metal chelates of polycarboxyalkylamine derivatives in which the alkyl carboxylic acid radicals are --CH 2 COOH.
A preferred metal chelate is a ferric chelate of N-(2-hydroxyethyl)ethylenediaminetriacetic acid (Fe-HEDTA).
In a preferred embodiment of the invention, the composition is incorporated with a carrier matrix, for example, a bibulous paper, to form a test means which can be affixed to an inert support to form a test device. In addition, a method for making, and a method for using the test means (and device) are provided by the invention.
The inclusion of a metal chelate, according to the invention described herein, provides the compositions, test means (and devices) not only with excellent resistance to ascorbate interference, but also with unexpectedly advantageous stability, as reflected by experimental findings of good storage and elevated temperature stability and a lack of "false positive" results.
DETAILED DESCRIPTION OF THE INVENTION
Initial wet chemical experiments during development of the instant invention, and which employed only the ferric chelate of N-2(hydroxyethyl)ethylenediaminetriacetic acid (herein referred to as Fe-HEDTA; this notation is used for convenience only and is not meant to imply the existence of a covalent bond between the metal ion and the polycarboxyalkylamine derivative), ascorbic acid and buffer, confirmed the rapidity of ascorbic acid oxidation in the presence of this chelate, a result which would be expected from the previously-described reports of Khan and Martell. Thus, in view of how much faster TMB has been shown to be oxidized in peroxidase containing compositions, by comparison with ascorbic acid oxidation by such compositions, it was expected that a composition incorporating an organic hydroperoxide, an oxidizable indicator such as TMB and additionally, such a metal chelate, would be extremely unstable, quickly rendering "false positive" results.
However, upon further experimentation, the discovery was made that a composition can be formulated which includes such metal chelates, is suitable for the detection of peroxidatively active substance, and, moreover, is adaptable to a dry, solid state format, exhibiting good reagent stability during manufacture and in storage and a lack of "false positive" results when contacted with known hemoglobin-negative urine. This achievement of the present invention runs counter to any suggestion of the aforedescribed art which, as previously discussed, suggests that metal chelates such as Fe-HEDTA can be used as "model peroxidases", and thus would be unsuitable for use in a composition to determine the concentration of a peroxidatively active analyte.
Test means (and devices) for the detection of occult blood (OB), i.e., hemoglobin, in biological fluids such as urine, which have been produced from the novel composition of the invention, have been found to be resistant to abnormally elevated ascorbic acid levels in urine. As previously discussed, inhibition due to ascorbic acid is a serious problem, particularly in view of the fact that some 25% of urine specimens can be expected to exhibit ascorbic acid levels greater than 10 milligrams per deciliter (mg/dL). Conventional OB devices which do not include an ascorbate interference retardant of some type are usually found to be inhibited (i.e., rendered less sensitive to the presence of hemoglobin) by ascorbic acid concentrations as low as 5 mg/dL. However, devices produced in accordance with the present invention are greatly advantageous, in terms of ascorbate interference resistance, over such conventional devices, enabling the detection of peroxidatively active substances in fluids which contain relatively high levels of ascorbic acid, for example, on the order of 50 mg/dL.
The present invention thus provides compositions, test means (and devices) and methods for the determination of peroxidatively active substances in biological fluids such as urine. In addition to hemoglobin, other peroxidatively active substances can be detected by compositions, test means (and devices) of the invention, including, for example, peroxidase, myoglobin, erythrocytes, and other pseudoperoxidases. The invention involves the use of a metal chelate which is a derivative of an polycarboxyalkylamine and which is also recognized as a "model peroxidase", for the purpose of reducing or eliminating the deleterious effects of ascorbic acid on analytical assays performed on biological fluids. In this respect, the metal chelate functions to facilitate the oxidation of ascorbate ion which may be present in such fluids.
Compositions, test means (and devices) of the invention have been found to be substantially less susceptible to ascorbate interference, and to produce a response which is visually or instrumentally detectable, e.g., a color response, to the presence of trace hemoglobin levels on the order of 0.03 mg/dL, or even less.
The organic hydroperoxide contemplated for use in the composition of the invention can be selected from many well known organic hydroperoxides. One selected must, however, be capable of interacting with a peroxidatively active substance in the presence of an indicator to produce a detectable response, such as a color change or a change in the amount of light absorbed or reflected by the test composition. Among hydroperoxides which are particularly suitable are cumene hydroperoxide, t-butyl hydroperoxide, diisopropylbenzene hydroperoxide, 2,5-dimethylhexane-2,5-dihydroperoxide, paramenthane hydroperoxide, and other well-known hydroperoxides which are suitable for oxidizing the indicator used, or mixtures of these compounds. Of the foregoing, cumene hydroperoxide is most preferred.
Many indicators are suitable for use in the composition of the invention, so long as they are capable of interaction to produce a detectable response in the presence of an organic hydroperoxide and a peroxidatively active substance. These include, for example, the so-called "benzidine-type" compounds; benzidine; o-tolidine; 3,3',5,5'-tetra(lower alkyl)benzidine; 2,7-diaminofluorene; and mixtures of these or various others. The term "lower alkyl", as used herein, refers to an alkyl radical having from 1 to 6 carbon atoms, including methyl, ethyl, n-propyl and isopropyl, and the various butyl, pentyl and hexyl isomers. The indicator, 3,3',5,5'-tetramethylbenzidine (TMB), is especially preferred.
The suitability of a particular metal chelate selected for use is governed not only by its ability to facilitate the oxidization of ascorbic acid, but also by its compatibility with the other constituents of the composition. Thus, such suitable chelates have been found to include metal chelates of polycarboxyalkylamine derivatives which are represented by the general formula: ##STR3##
Accordingly, exemplary metal chelates which have been found suitable for use in the instant invention include the ferric chelates of N-(2-hydroxyethyl)-ethylenediaminetriacetic acid (Fe-HEDTA), ethylenediaminetetraacetic acid (Fe-EDTA), cyclohexylenediaminetetraacetic acid (Fe-CDTA), nitrilotriacetic acid (Fe-NTA), iminodiacetic acid (Fe-IMDA), ethylenediaminediacetic dipropionic acid (Fe-EDDP) both α and β forms), and hydroxyethyliminodiacetic acid (Fe-HIMDA) and mixtures thereof. The ferric chelate forms are generally preferred; most preferred are the compounds Fe-HEDTA and Fe-EDTA, most desirable is Fe-HEDTA. However, many suitable chelates are within the scope of the present invention in addition to those specifically set forth herein, as will be apparent to one of reasonable skill in the art, given the present teachings.
Accordingly, it has been found experimentally that Fe-HEDTA and Fe-EDTA, and particularly Fe-HEDTA, provide excellent results in compositions, test means (and devices) of the invention, most satisfactorily providing ascorbic acid interference resistance in occult blood tests (enabling the detection of hemoglobin), while providing good reagent stability prior to use and a lack of "false positive" results. Moreover, other metal chelate compounds herein specified, as well as many others, will perform satisfactorily. However, substantial variations in the rate at which a peroxidatively active substance can be detected when such other compounds are used, can be expected because of varying rates of ascorbate oxidation. Thus, it is to be understood that suitable metal chelates for use in the instant invention can be selected from any which are polycarboxyalkylamines derivatives within the class of compounds previously described, and that all such compounds can be expected to satisfactorily enable oxidation of ascorbate, placing them within the scope of the present invention. However, many in this regard will perform slowly and thus are less practical for commercial use and not preferred.
Suitable metal chelates for use in the present invention can be prepared by conventional laboratory procedures using polycarboxyalkylamine derivatives which are commercially available from Aldrich Chemical Co., Sigma Chemical Company or similar suppliers. For example the metal chelate, Fe-HEDTA, can be prepared by mixing equimolar amounts of commercially available HEDTA and FeCl 3 .6H 2 O, in aqueous solution, to produce a 1:1 (mole:mole) Fe-HEDTA solution of iron:chelate. Other solution concentration ratios of metal:chelate can be easily prepared merely by varying the respective concentrations of the mixed solutions. It has been found that best results in terms of overcoming ascorbate interference are obtained when the concentration of metal ion to polycarboxyalkylamine derivative in the chelate is approximately a 1:1 (mole:mole) relationship.
A preferred range of concentration of a given metal chelate in different embodiments of the invention will vary widely. For example, in the case of Fe-HEDTA, a preferred concentration range presently is from about 0.5 millimolar (mM) to about 50 mM when used in a composition containing an organic hydroperoxide and a tetra(lower alkyl)benzidine indicator; this range has been determined to be optimum for resistance up to about a 50 mg/dL ascorbate concentration level in urine samples. Moreover, in experimental trials, lower concentrations of some suitable ferric chelates enabled comparatively rapid hemoglobin detection, whereas higher concentrations of the same chelates, or of other chelates, were less effective. These apparently anomolous results are more fully set forth, infra, and demonstrate the lack of a general correlation between chelate concentration and functionality or suitability in the composition of the invention.
It has been found experimentally that the majority of suitable metal chelates performing satisfactorily in the composition of the invention structurally possess an alkyl amine, or an amine central group, and also the carboxylic acid radical, --CH 2 COOH. However, other chelates not having such characteristics, but which are within the general scope of compounds previously set forth, can be generally effective to overcome ascorbate interference and provide satisfactory sensitivity and stability, and are therefore, satisfactory for use.
It is to be appreciated that, in use, the performance of a particular embodiment of a composition, test means (and device) based upon the general concepts of the invention depends on many different factors. Since a typical urine specimen from a human subject accustomed to ingesting large quantities of ascorbic acid (Vitamin C) often contains from 25 to 100 or more mg/dL of ascorbate; a reference ascorbate level for research purposes has been selected to be approximately 50 mg/dL. Preferred embodiments of the ascorbate resistant composition, test means (and device) and method of the invention have been found to enable the detection of peroxidatively active substances in such specimens not only at the reference level of about 50 mg/dL, but also at various other ascorbate levels. In most cases, a prolonged response time may occur with ascorbate levels much greater than the chelate concentration level. As set forth, infra, "lag times", i.e., the time until an observable response occurs, have been found experimentally to range from less than 1/3 minute to about 1/2 hour, for preferred embodiments of the invention of differing chelate concentration levels which were tested for ability to detect hemoglobin in urine in the presence of a level of 50 mg/dL ascorbate.
In a preferred embodiment, the composition of the invention is used to produce test means (and devices) for the determination of a peroxidatively active substance. In such preferred embodiment, the composition can be incorporated with a suitable carrier matrix to form a test means. The carrier matrix can take on many forms, such as those disclosed in U.S. Pat. No. 3,846,247 (felt, porous ceramic strips, and woven or matted glass fibers). Also suitable are the matrices described in U.S. Pat. No. 3,552,928 (wood sticks, cloth, sponge material and argillaceous substances). The use of synthetic resin fleeces and glass fiber felts as carrier matrices is suggested in British Pat. No. 1,369,139; another British Pat. No. 1,349,623, proposes the use of light-permeable meshwork of thin filaments as a cover for an underlying paper matrix. Polyamide fibers are disclosed in French Pat. No. 2,170,397. Such disclosures notwithstanding, the materials conventionally used as carrier matrices, and which are especially preferred and suitable for use in the present invention, are bibulous materials such as filter paper and the like. It is to be appreciated, however, that the carrier matrix can appear in various physical forms as summarized above, as well as others, and that all such forms are suitable and intended for use in the present invention.
In the preparation of the test means of the invention, the constituents of the composition can be incorporated with the carrier matrix in a variety of ways. For example, the constituents can be dissolved or suspended in water or another suitable solvent, preferably an organic one such as ethanol, acetone or dimethylformamide (DMF), as well as mixtures of these solvents and of others. The solution or suspension can then be used to impregnate bibulous filter paper, as in the form of an ink wherein the reagents are printed on a suitable matrix; alternatively, the carrier matrix can be immersed in or coated with the composition, such as with a doctor blade.
The presently preferred method of incorporation of the constituents of the composition with the carrier matrix is to impregnate bibulous filter paper with two or more solutions or suspensions of the constituents. Impregnation thus is accomplished by dipping a piece of filter paper two or more times into such solutions or suspensions and drying the dipped paper in an oven after each dip. The test means thus formed is then laminated to one side of a piece of double faced adhesive tape, the laminate is slit into strips and each strip attached to an elongated sheet of plastic backing material (such as polystyrene) which is then slit parallel to its short dimension to form oblong devices with the impregnated paper at one end, the other end serving as a handle. The test device thus formed consists of a piece of the doubly dried and impregnated test means affixed, at one end, to one flat side of an elongated plastic support which then forms a convenient handle.
One preferred method for making the test means of the invention is wherein, for example, Fe-HEDTA is introduced into the filter paper along with the organic hydroperoxide but prior to addition of the indicator, in an aqueous first dip. Thus, the filter paper can be first impregnated with an aqueous solution of Fe-HEDTA and the hydroperoxide, along with one or more suitable solvents and/or buffers, e.g., triethanolamine borate and Tris(hydroxymethyl)amino methane-malonate (referred to herein as TRIS-malonate), dried, reimpregnated in a second dip solution of the indicator in a suitable solvent, for example, ethanol, and dried a second time. Such a "two-dip" process, where the metal chelate is first impregnated into the paper before the other active reagents, has been found to yield a test device exhibiting excellent ascorbate resistance and storage stability.
An especially preferred method for formulating the test means of the invention is to introduce the metal chelate and the reagents, except for the indicator, into the filter paper by immersing it in a first solution of the reagents as previously described, and thereafter drying the paper and subsequently adding the indicator via immersion of the dried paper into a solution of the indicator and a thickening agent, such as polyvinylpyrrolidone, in a suitable solvent, followed by a second drying.
In addition to the previously described test composition reagents and other ingredients, other components, such as various thickening agents, wetting agents, buffers, emulsifying agents and well known adjuvants can also be included in the composition, test means (and device) of the present invention. Thus, for example, as thickening agents, there can be used various materials in addition to or in place of polyvinylpyrrolidone, such as gelatin, algin, carrageenin, casein, albumin, methyl cellulose and the like. As wetting agents, it is preferable to use sodium dodecyl sulfate but any long chain organic sulfate or sulfonate, such as dioctyl sodium sulfosuccinate or sodium dodecylbenzene sulphonate can also be used. For the buffering systems, in addition to triethanolamine borate and TRIS-malonate, tartarate, phosphate, phthalate, citrate, acetate, succinate or other buffers can be employed. Preferably, the compositions are buffered to a pH value of from about 6.0 to 7.0. As emulsifying agents, polyvinyl alcohol, gum arabic, carboxy vinyl polymers and the like can be used. The organic solvents which are useful to suspend the indicator include most nonreactive, organic volatile solvents such as ethanol, acetone, DMF, chloroform, ethylene dichloride, benzene, ethyl acetate and the like. Of course the choice of other suitable solvents is within the ability of one skilled in the art given the present disclosure.
In use, the test means (or test device) can be immersed in the fluid or liquid suspension of the material to be tested and immediately withdrawn; or the sample, in liquid, solid or semi-solid form, can be applied to the test means (or device). In the presence of a peroxidatively active substance in the sample, the test composition produces a color change or other detectable response. If the response is color, it can be compared with precalibrated color standards for an estimation of the quantitative amount of peroxidatively active substance contained in the sample. Intact peroxidatively active substances, such as intact red blood cells, can appear as dots or flecks of color on the otherwise uncolored matrix. Hemolyzed peroxidatively active substances can uniformly color the matrix. In addition to visual comparison, various instrumental methods can also be employed to determine the quality of the color or other response developed, thus increasing the accuracy of the test by obviating the subjective determination of the human eye.
The following Examples are provided only in order to illustrate the concepts and advantages of the presently disclosed invention, and are not to be construed as imposing limitations upon the scope thereof. Any such limitations are intended to be defined solely by the claims appended hereto.
EXAMPLES
A. THE TEST COMPOSITION
EXAMPLE I--Fe-HEDTA
An experiment was conducted wherein the composition of the present invention, capable of determining the presence of peroxidase or another peroxidatively active substance in a test sample, and in particular hemoglobin, was prepared. The composition included, as an ascorbate interference retardant, a 1:1 (mole to mole indicated as M:M herein) ferric chelate of N-(2-hydroxyethyl)ethylenediaminetriacetic acid (Fe-HEDTA). The Fe-HEDTA chelate was prepared by dissolving 0.278 gram (g) of HEDTA in 100 milliliters (mL) of distilled water to produce a 10 millimolar (mM) HEDTA solution, and then dissolving 0.270 g of FeCl 3 .6H 2 O into the 10 mM HEDTA solution. Ascorbic acid, at a concentration of 5 mM, was added to the composition in an amount sufficient to produce a 50 micromolar concentration level in the final volume of the solution. The constituents of the composition and the ascorbic acid were combined in the order and in the amounts listed in the following table. The final composition solution contained a 100 micromolar (μM) concentration of Fe-HEDTA, a concentration level, like the level of the other ingredients present, substantially less than would be used in a similar composition of the invention for incorporation into a solid state test means or device.
______________________________________0.2 Molar (M) sodium citrate buffer 9.5 mL10 mM Fe--HEDTA 0.1 mL10 g/dL* sodium dodecyl sulfate 0.1 mL1 M cumene hydroperoxide 0.1 mL10 mM 3,3',5,5'-tetramethylbenzidine 0.1 mL5 mM ascorbic acid 0.1 mL______________________________________ *grams per deciliter
The composition of the invention so produced was observed to form a blue color when an aqueous blood aliquot was added to produce a final concentration of 0.139 milligram of hemoglobin per deciliter in the solution, indicating the ability of the composition to detect the hemoglobin present despite the 50 μM ascorbate level of the sample.
EXAMPLE II--Fe-EDTA
The experiment of Example I was repeated except that 10 mM of the ferric chelate of ethylenediaminetetraacetic acid (Fe-EDTA) solution was used, rather than Fe-HEDTA. The Fe-EDTA was prepared substantially as described in Example I, by dissolving 0.292 g of EDTA in 100 mL of distilled water and adding FeCl 3 .6H 2 O, as described in Example I. The composition so produced formed a blue color, as in Example I, in the presence of 0.139 milligram of hemoglobin per deciliter and 50 μM ascorbate.
EXAMPLE III--Fe-CDTA
The experiment of Example I was repeated except that 10 mM of the ferric chelate of cyclohexylenediaminetetraacetic acid (Fe-CDTA) solution was used, rather than Fe-HEDTA. The Fe-CDTA solution was prepared by dissolving 0.346 g of CDTA in 100 mL of distilled water and adding FeCl 3 .6H 2 O, as described in Example I. The composition so produced formed a blue color, as in Example I, in the presence of 0.139 milligram of hemoglobin per deciliter and 50 μM ascorbate.
EXAMPLE IV--Fe-IMDA
The experiment of Example I was repeated except that 10 mM of the ferric chelate of iminodiacetic acid (Fe-IMDA) solution was used, rather than Fe-HEDTA. The Fe-IMDA solution was prepared by dissolving 0.133 g of IMDA in 100 mL of distilled water and adding FeCl 3 .6H 2 O, as described in Example I. The composition so produced formed a blue color, as in Example I, in the presence of 0.139 milligram of hemoglobin per deciliter and 50 μM ascorbate.
EXAMPLE V--Fe-NTA
The experiment of Example I was repeated except that 10 mM of the ferric chelate of nitrilotriacetic acid (Fe-NTA) solution was used, rather than Fe-HEDTA. The Fe-NTA solution was prepared by dissolving 0.191 g of NTA in 100 mL of distilled water and adding FeCl 3 .6H 2 O, as described in Example I. The composition so produced formed a blue color, as in Example I, in the presence of 0.139 milligram of hemoglobin per deciliter and 50 μM ascorbate.
EXAMPLE VI--Fe-EDDP.sub.α
The experiment of Example I was repeated except that 10 mM of the ferric chelate of α-ethylenediaminediacetic dipropionic acid (Fe-EDDP.sub.α) solution was used, rather than Fe-HEDTA. The Fe-EDDP.sub.α solution was prepared by dissolving 0.320 g of EDDP.sub.α in 100 mL of distilled water, and adding FeCl 3 .6H 2 O, as described in Example I. The composition so produced formed a blue color, as in Example I, in the presence of 0.139 milligram of hemoglobin per deciliter and 50 μM ascorbate.
EXAMPLE VII--Fe-EDDP.sub.β
The experiment of Example I was repeated except that 10 mM of the ferric chelate of β-ethylenediaminediacetic dipropionic acid (Fe-EDDP.sub.β) solution was used, rather than Fe-HEDTA. The Fe-EDDP.sub.β solution was prepared by dissolving 0.320 g of EDDP.sub.β in 100 mL of distilled water, and adding FeCl 3 .6H 2 O, as described in Example I. The composition so produced formed a blue color, as in Example I, in the presence of 0.139 milligram of hemoglobin per deciliter and 50 μM ascorbate.
EXAMPLE VIII--Fe-HIMDA
The experiment of Example I was repeated except that 10 mM of the ferric chelate of hydroxyethyliminodiacetic acid (Fe-HIMDA) solution was used, rather than Fe-HEDTA. The Fe-HIMDA solution was prepared by dissolving 0.177 g of HIMDA in 100 mL of distilled water, and adding FeCl 3 .6H 2 O, as described in Example I. The composition so produced formed a blue color, as in Example I, in the presence of 0.139 milligram of hemoglobin per deciliter and 50 μM ascorbate.
EXAMPLES IX-XVI
Experiments were conducted substantially as described in Examples I-VIII, supra, to produce compositions according to the invention, except that in each case 9.4 mL of 0.2M sodium citrate buffer was used rather than 9.5 mL, and 0.2 mL of each ferric chelate was used, rather than 0.1 mL. This enabled a 200 μM concentration level of the ferric chelate to be present in each composition. In each case, the composition containing 200 μM ferric chelate, when tested as previously described, were observed to form blue colors in the presence of 0.139 milligram of hemoglobin per deciliter and 50 μM ascorbate, indicating an ability to detect the hemoglobin despite the presence of ascorbate in the sample. However, differences were noted between the times required for color to form, by comparison with the color formation times observed when the 100 μM ferric chelate compositions of Examples I through VIII were similarly tested. The color formation times in each case, referred to as "lag times", are set forth in the following table, and show that, as previously described, there appears to be no general relationship or correlation between the concentration of metal chelate, e.g., one of the foregoing ferric complexes, which is used in a composition of the invention and the ability of the composition to withstand ascorbate interference and allow the detection of a peroxidatively active substance.
__________________________________________________________________________EXPERIMENTAL RESULTS:Color Formation, Lag Time(50 μM ascorbate) METAL CHELATE CONCENTRATIONEXAMPLE METAL CHELATE: 100 μM 200 μMNOS. 1:1 (M:M) Fe.sup.3+ --Chelate EXAMPLES I-VIII EXAMPLES IX-XVI__________________________________________________________________________I and IX Fe.sup.3+ --HEDTA 18 sec not doneII and X Fe.sup.3+ --EDTA 67 sec not doneIII and XI Fe.sup.3+ --CDTA 3 min 21/2 minIV and XII Fe.sup.3+ --IMDA 5 min 7 minV and XIII Fe.sup.3+ --NTA 15 min 5 minVI and XIV Fe.sup.3+ --EDDP.sub.α 18 min 10 minVII and XV Fe.sup.3+ --EDDP.sub.β 31 min 19 minVIII and XVI Fe.sup.3+ --HIMDA 20 min 20 min__________________________________________________________________________
B. THE TEST DEVICE
EXAMPLE XVII
An experiment was conducted wherein a solid state test device was prepared in accordance with the instant invention. The device comprised a paper carrier matrix incorporated with the composition of the invention as described in Example I, supra, except that the concentrations of the ingredients were varied to suit the solid state device format. Incorporation of the matrix with the composition and formation of the test device were carried out using the following procedures.
A 50 mM, 1:1 (mole:mole) ferric chelate of N-(2-hydroxyethyl)ethylenediaminetriacetic acid (Fe-HEDTA) was prepared by dissolving, in 100 mL of distilled water, 1.39 g N-(2-hydroxyethyl)ethylenediaminetriacetic acid, and then adding to the solution 1.35 g of FeCl 3 .6H 2 O.
Two solutions (composition follows) were prepared. To produce the test means, a piece of Whatman 3 MM filter paper having approximate dimensions of 6 inches by 4 inches was then impregnated with the reagent solutions, so that the paper became fully incorporated with the reagent composition after the second dip. The procedure used involved impregnating the paper by immersing it in the first solution, drying the impregnated paper, and subsequently further impregnating the dried paper by immersion in the second solution followed by a final drying. Drying was accomplished in a forced draft oven at 105° C. for about 8 minutes after the first impregnation, and at 50° C. for about 5 minutes following the second impregnation.
The first reagent solution was prepared by mixing the following ingredients:
______________________________________Distilled water 74.0 mL1 M TRIS-malonate buffer, 10.0 mLpH 6.55.5 M cumene hydroperoxide 4.0 mL10 g/dL sodium dodecyl sulfate 2.0 mL50 mM Fe--HEDTA (prepared 10.0 mLas previously described______________________________________
The second reagent solution was prepared by mixing the following ingredients:
______________________________________Ethanol 79.4 mL6-methoxyquinoline, free 0.6 mLbase form20% (w/v) polyvinylpyrrolidone 20.0 mL(aqueous) (molecular wt.40,000)3,3',5,5'-tetramethylbenzidine 0.6 g______________________________________
The dried, impregnated paper was laminated to one side of a piece of double-sided adhesive transfer tape, commercially available from 3M Company, St. Paul, Minn. 55144. The laminate was then slit into portions measuring about 6 inches by 0.2 inches. One of these was attached, via the unused adhesive side, to a polystyrene sheet measuring about 3.5 inches by 6 inches and the resulting laminate was slit parallel to its short dimension to form test devices comprising a 3.5 inch oblong polystyrene strip carrying a square of the impregnated paper at one end, the other end serving as a handle.
Testing of devices produced according to the procedure of Example XVII, in urine samples which contained various concentration levels of hemoglobin and a 50 mg/dL concentration of ascorbate, yielded easily discernible blue color levels corresponding to the various hemoglobin levels, indicating the ability of the device to detect the hemoglobin present despite the high ascorbate levels of the samples.
EXAMPLE XVIII
The experiment of Example XVII was repeated, except that 10.0 mL of a 50 mM Fe-EDTA solution were used in the first reagent solution, in place of Fe-HEDTA.
Testing of devices, produced in accordance with Example XVIII, was carried out as previously described in urine samples containing various concentration levels of hemoglobin and 50 mg/dL ascorbate, and yielded easily discernible blue color levels corresponding to the various hemoglobin levels.
EXAMPLE XIX
The experiment of Example XVII was repeated, except that 10.0 mL of a 50 mM Fe-CDTA solution were used in the first reagent solution, in place of Fe-HEDTA.
Testing of devices, produced in accordance with Example XIX, was carried out as previously described in urine samples containing various concentration levels of hemoglobin and 50 mg/dL ascorbate, and yielded easily discernible blue color levels corresponding to the various hemoglobin levels.
EXAMPLE XX
The experiment of Example XVII was repeated, except that 10.0 mL of a 50 mM Fe-IMDA solution was used in the first reagent solution, in place of Fe-HEDTA.
Testing of devices, produced in accordance with Example XX, was carried out as previously described in urine samples containing various concentration levels of hemoglobin and 50 mg/dL ascorbate, and yielded easily discernible blue color levels corresponding to the various hemoglobin levels.
EXAMPLE XXI
The experiment of Example XVII was repeated, except that 10.0 mL of a 50 mM Fe-NTA solution was used in the first reagent solution, in place of Fe-HEDTA.
Testing of devices, produced in accordance with Example XXI, was carried out as previously described in urine samples containing various concentration levels of hemoglobin and 50 mg/dL ascorbate, and yielded easily discernible blue color levels corresponding to the various hemoglobin levels.
C. TEST DEVICE ASCORBATE INTERFERENCE RESISTANCE AND STABILITY
Further experiments were conducted to assess the ability of test devices, prepared as described in Example XVII, supra, to detect hemoglobin in urine in the presence of ascorbate after stress designed to mimic long storage. The experiments were conducted on some of the devices immediately after they had been freshly prepared, as well as on others after they had been stored for extended periods under elevated temperature conditions. In particular, the devices were tested and compared for performance immediately after preparation at ambient temperature (about 23° C.), and after ten (10) and twenty-eight (28) days of "heat stress" at about 50° C. in an oven.
A set of test urine solutions was formulated which contained various levels of hemoglobin. Two hemoglobin solutions were also prepared which contained ascorbate at a concentration level of 50 mg/dL.
A stock solution was prepared containing 15.4 mg/dL of hemoglobin, by diluting whole blood, with distilled water to a concentration of 15.4 mg hemoglobin per 100 mL water. The hemoglobin content of the whole blood had been previously determined by conventional techniques. A sample of pooled urine, previously screened to be negative in hemoglobin and ascorbic acid, was set aside as a blank. The test solutions were then prepared by pipetting aliquots of the blood solution into the pooled urine to form urine solutions containing 0.015, 0.031, 0.062 and 0.139 mg/dL hemoglobin. Part of the urine solutions having 0.031 and 0.062 mg/dL hemoglobin were isolated in separate containers, and ascorbic acid was added thereto to bring the solutions to a level of 50 mg/dL ascorbate immediately prior to the testing.
A set of devices, prepared as in Example XVII, as well as a control set of devices prepared as described in that Example with the exception that they included no Fe-HEDTA, were tested in the blank and in each of the hemoglobin/urine solutions. The devices were momentarily immersed in each solution, then removed and color formation in the devices observed after one minute. The colors which formed were visually compared with one another and with a standard color chart, for relative intensity at one minute after immersion. The colors ranged from none (with the blank) to dark greenish-blue with the 0.139 mg/dL hemoglobin solution.
The results of this testing, summarized in the following table, show that test devices according to the present invention, tested in the two hemoglobin samples containing ascorbate both after being freshly prepared and after exposure to an elevated temperature of 50° C. for 10 days, elicited color responses to the presence of hemoglobin similar to the responses of the devices used to test the urine samples without ascorbate. The results from similar testing of the control devices which did not include Fe-HEDTA, showed the response of the control devices was virtually completely impaired by ascorbate in the sample. However, the devices produced according to this preferred embodiment of the invention evidenced an ability to easily detect hemoglobin at concentrations of 0.031 and 0.062 mg/dL, despite the presence of an ascorbate concentration of 50 mg/dL. Thus, the presence of the Fe-HEDTA appeared to dramatically curtail ascorbate interference.
__________________________________________________________________________STABILITY PERFORMANCE OF TEST STRIP DEVICESOF THE INVENTION CONTAINING FE--HEDTA Freshly-prepared Freshly-prepared Strip devices Strip devices strip devices atUrine sample strip devices at stored at 50° C. stored at 50° C. ambient temp. with-Hemoglobin (mg/dl) ambient temp.* for 10 days* for 28 days* out Fe--HEDTA* (Controls)__________________________________________________________________________(no ascorbic acid)0 (Blank) 10 10 10 100.015 20 20 15 220.031 25 25 22 300.062 32 30 30 350.139 45 40 38 40(50 mg/dl ascorbicacid)0.031 25 22 20 100.062 32 30 28 10__________________________________________________________________________ *The numbers in the table refer to test strip device performance as gauge by a standard color chart for existing occult blood strips. The chart is available from the Ames Division of Miles Laboratories, Inc. on the labelling for the occult blood test available as HEMASTIX ® On this color chart, a value of "10" is a negative reading, a "20" indicates trac hemoglobin or 0.015 mg/dL, and 30 and 40 correspond to 0.046 and 0.139 mg/dL hemoglobin, respectively.
The results from the foregoing table also demonstrate that there was little difference in reactivity between test devices of the present invention which had been freshly prepared and those which had been stored at 50° C. for 10 or 28 days. This result runs counter to the anticipated result: that interaction of ferric chelate and a hydroperoxide in same test device would cause a decrease in the device reactivity at a more rapid rate under heat stress than when stored at ambient temperature. This demonstrates the good stability and advantageous "shelf-life" of the composition and device of the invention. As seen from the data, there was little or no incompatibility evident between the organic hydroperoxide and Fe-HEDTA, between Fe-HEDTA and the indicator, or between these substances and other strip ingredients, even after prolonged storage at elevated temperatures. Moreover, metal chelate (Fe-HEDTA)-containing test devices, and devices similarly prepared without Fe-HEDTA, were substantially similar in sensitivity to the presence of hemoglobin in test solutions without ascorbate and showed a lack of "false positive" results, indicative of the outstanding compatibility of the reagents. However, while the devices prepared without Fe-HEDTA were virtually completely inhibited by the presence of ascorbate in the test solutions, the strips of the invention containing Fe-HEDTA were much less inhibited by the ascorbate and, in fact, were able to respond, by the appearance of visually discernible color after one minute, to hemoglobin levels as low as 0.031 and 0.062 mg/dL.
In order to further demonstrate the advantages of the present invention, additional experimental testing similar to that aforedescribed was conducted with devices prepared as in Example XVII, i.e., containing Fe-HEDTA. However, rather than utilizing a visual technique, color formation was followed using a device known as the "Rapid Scanner". This device is a scanning reflectance spectrophotometer interfaced with a laboratory microcomputer. The instrument is used for the rapid measurement of reflectance spectra in the visual range. The computer enables the storage of spectral data and performs computations. Measurements of the performance of reagent strips in the Rapid Scanner have, for example, the following advantages over visual observation of the same strips:
1. The light source and conditions surrounding the sample remain fixed. In visual observations, the light source can vary, not only in wavelength, but also in relation to the location of the strip being observed.
2. The detector characteristics remain fixed. In visual observation, the detector (i.e., the eyes of the observer) can vary from person to person, and with the same person, from day to day.
3. The Rapid Scanner enables more precise quantitation of the data than does visual observation thereby permitting comparisons between results to be made in a more objective manner.
The Rapid Scanner instrument was constructed by the Ames Division of Miles Laboratories, Inc., Elkhart, Ind., from whom complete information with respect to structural and performance characteristics is obtainable. See also, M. A. Genshaw and R. W. Rogers, Anal. Chem., Vol. 53, pp. 1949-1952 (1981).
Tri-stimulus values from the Rapid Scanner were used to calculate color difference values (ΔE) according to the convention contained within "Supplement No. 2 to Commission Internationale de L'Eclairage (Paris, France) Publication No. 15, Colorimetry, (E.-1.3.1) 1971." The data from this instrument are, therefore, recorded below in terms of ΔE, or color difference units.
The test strip devices according to the invention which contained Fe-HEDTA were tested using the aforedescribed procedures for ability to detect hemoglobin concentrations of 0.031 mg/dL and 0.062 mg/dL. Some of the devices were tested in urine samples containing 50 mg/dL ascorbate, some in similar samples which did not contain ascorbate, some after being freshly prepared at ambient temperature, and some after storage at ambient temperature and 50° C., for 11 and 28 day periods.
The color difference units (ΔE) provided by the Rapid Scanner correspond to various hemoglobin levels. When the devices containing Fe-HEDTA were tested in urine samples containing 0.031 and 0.062 mg/dL hemoglobin, with and without ascorbate present, the results were as shown in the following series of tables:
______________________________________Urine Sample AscorbicHemoglobin Acid Rapid Scanner Results (ΔE)(mg/dL) (mg/dL) Test Device______________________________________FRESHLY PREPARED DEVICES0.031 0 21.890.031 50 15.750.062 0 29.780.062 50 22.84DEVICES STORED AT AMBIENT TEMPERATUREFOR TWENTY-EIGHT (28) DAYS0.031 0 15.500.031 50 13.290.062 0 26.310.062 50 18.20DEVICES STORED AT 50° C. FORELEVEN (11) DAYS0.031 0 20.860.031 50 12.360.062 0 30.040.062 50 27.26DEVICES STORED AT 50° C. FORTWENTY-EIGHT (28) DAYS0.031 0 10.310.031 50 7.780.062 0 20.860.062 50 16.38______________________________________
The foregoing experiments present instrumental data which corroborate the visual data presented, supra. The data shows the stability of devices of the invention as well as a significant abatement of ascorbate interference in such devices even after prolonged storage and storage at elevated temperatures.
Additional visual testing was conducted on a set of test devices which had been prepared according to the invention as described in Example XVIII, supra, i.e., which contained Fe-EDTA. Following preparation of the devices, they were tested in urine samples conaining various concentrations of hemoglobin, and no hemoglobin, and in samples of two hemoglobin levels which contained 50 mg/dL ascorbate. Some of the devices were tested immediately after preparation, and some after storage in an oven at 50° C. for twenty-eight (28) days. The results of this testing are presented in the following table, wherein the numbers correspond to visual color values obtained by reference to the aforementioned HEMASTIX® standard color chart. All testing of these devices were carried out as previously described.
______________________________________STABILITY PERFORMANCE OF TEST STRIPDEVICES OF THE INVENTION CONTAININGFe--EDTAUrine Sample Freshly-preparedHemoglobin strip devices Strip devices stored(mg/dL) at ambient temp. at 50° C. for 28 days______________________________________(no ascorbic acid)0 10 100.015 12 110.031 20 150.062 30 220.139 35 30(50 mg/dLascorbic acid)0.031 20 140.062 30 22______________________________________
The results of these latter tests confirm the stability, lack of false positive results, and substantial ascorbate inhibition resistance of devices produced according to this further embodiment of the invention.
It is apparent that many modifications and variations from the preferred embodiments of the invention specifically disclosed may be possible without departing from the spirit and scope thereof. Accordingly, it is intended that any limitations be imposed imposed upon the invention only as set forth in the following claims.
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A composition, test means (and device) and method for determining peroxidatively active substances in a test sample are disclosed. The composition, test means (and device) and method are rendered resistant to the adverse affects of ascorbate which may be present in the sample by the inclusion in the composition of a metal chelate which is polycarboxyalkylamine derivative having the formula: ##STR1## where: (a) R 1 is hydrogen or straight or branched chain alkyl alcohol or alkyl carboxylic acid radicals having from 2 to 3 carbon atoms; R 2 , R 3 , R x and R y , same or different, are straight or branched chain alkyl alcohol or alkyl carboxylic acid radicals having from 2 to 3 carbon atoms; where at least two of R 1 , R 2 , R 3 , R x or R y are alkyl carboxylic acid radicals so defined;
(b) R p and R q , same or different, are straight or branched chain alkylene radicals having from 1 to 3 carbon atoms or divalent 1,2-cycloaliphatic radicals having from 6 to 9 carbon atoms;
(c) n is an integer having a value of from 0 to 1; m is an integer having a value of from 0 to 2; where if m is greater than 0, repeated R p and repeated R q radicals may be the same or different; and
(d) M is Fe +3 .
The composition also comprises an organic hydroperoxide and an indicator capable of providing a detectable response in the presence of peroxide and the peroxidatively active substance. The test means comprises a carrier matrix incorporated with the composition, and the method comprises immersing the test means (or device) in the test sample and observing a color or other detectable response.
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[0001] This application is continuation of co-pending application Ser. No. 11/160,303, filed Jun. 17, 2005, entitled “Synthetic Roundsling with Inspectable Core,” and claims the benefit of provisional application Ser. No. 60/581,131, filed Jun. 19, 2004, entitled “Roundsling with Inspectable Core.” The contents of these prior applications are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates to synthetic roundslings.
BACKGROUND OF THE INVENTION
[0003] Industrial slings are an important tool in lifting and moving heavy loads. Lifting slings are fabricated of alloy steel chain, wire rope, metal mesh, synthetic fiber rope, synthetic webbing, and synthetic fiber yarns enclosed in a protective cover. Slings are also available in a variety of configurations, including single and mulit-leg bridle slings, eye-and-eye slings, and endless loop slings, known as roundslings. The type of sling used for a particular job depends on several factors, including the weight and nature of the load, and the temperature and chemical content of the environment.
[0004] Steel slings are resistant to high temperatures and inert to many chemicals, but they are heavy and stiff and likely to damage the exterior surface of the loads. While synthetic slings have temperature and weight-bearing limits below those of comparable steel slings, they offer a highly flexible and lightweight alternative in appropriate applications. The flexible fibers closely grip the contours of a load and are less likely to damage the load's exterior. The synthetic material can be color coded to reduce the likelihood of improper use, and it is not susceptible to corrosion. Synthetic slings do not require grease and, consequently, no gloves are needed to handle them.
[0005] A synthetic roundsling has a core formed of a number of endless loops of synthetic yarn contained in a synthetic sleeve or cover. The inner core yarn provides the strength to lift the load, and the cover protects the core and comes into contact with the load. The weight bearing points in a roundsling vary with each use, as compared to a rope sling, for example, on which the lift the points are fixed at the eyes of the sling.
[0006] These core fibers, however, are susceptible to damage from abrasion or sharp edges and to degradation from exposure to heat, caustic chemicals, or other environmental pollutants. The core yarn may be damaged when the sling is not rotated between uses so that the same wear points are permitted to stay in contact with the device used for lifting, such as hooks on a crane. In addition, malfunction may occur as a result of manufacturing defects, defective core yarns, or friction between the hidden core yarns that cannot be inspected in existing slings. For these reasons, frequent and adequate inspection of roundslings is important to detect perceptible damage and defects.
[0007] On most types of slings, such as chain slings for example, the load bearing elements are continuously open to inspection before, during and after use. However, inspection of a synthetic roundsling is problematic. The protective cover prevents direct inspection of the load-bearing fibers inside.
[0008] Criteria have been developed for determining when a synthetic roundsling should be removed from service. For example, if acid or caustic burns or heat damage is seen on the cover, or the cover exhibits tears or snags, the sling should be removed from service. Presently, all inspection criteria of synthetic roundslings relate to the condition of the cover or to the core yarns visible through an opening in the cover. In other words, direct inspection of the core fibers is not possible until the cover has already suffered damage.
[0009] Several useful techniques and devices have been developed for indicating the likely condition of the hidden core yarns. For example, some synthetic roundslings are equipped with fiber optic filaments with “tell tails” extending through the cover. The tell tails indicate that the sling has experienced over stretching or that other abuse has occurred that may have damaged the core. Though these advances are useful, there remains a need for a synthetic roundsling in which the core yarns can be inspected directly, frequently and entirely.
SUMMARY OF THE INVENTION
[0010] The present invention comprises a synthetic roundsling. The roundsling comprising a load-bearing core formed of a plurality of endless loops of synthetic, non-metallic material. The core is contained within a tubular cover formed of transparent material through which the condition of substantially the entire core is viewable.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a plan view of a roundsling made in accordance with the present invention.
[0012] FIG. 2 is an enlarged fragmented view of the roundsling of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] Turning now to the drawings in general and to FIG. 1 in particular, there is shown therein a roundsling made in accordance with the present invention and designated generally by the reference numeral 10 . As shown in FIG. 2 , the roundsling 10 comprises a load-bearing core 12 contained within a tubular cover 14 .
[0014] The load-bearing core 12 is formed of synthetic fibers. Preferably, the core 12 comprises a plurality of endless loops of synthetic, non-metallic material. By way of example, the fibers may be formed of nylons, polyesters, polyethylenes or polypropylenes, or a combination of any of these. For example, the fibers may be formed of a high density polyethylene polymer sold by Honeywell International, Inc. under the SPECTRA. Alternately, the load lifting core yarn may comprise synthetic poly(ethylene terephthalate) fiber sold by the DuPont Company under the brand name DACRON.RTM, or a synthetic aramid polymer material, such as poly(p-phenylene terephthalamide) sold by the DuPont Company under the brand name KEVLAR.RTM, a para-linked aramid material, such as TECHNORA sold by Teijin Kabushiki Kaisha of Japan. Still further, the core fibers may comprise a combination of any of these.
[0015] The tubular cover 14 that contains the core yarns 12 is selected for its general ability to protect the yarns inside and to provide an abrasion resistant surface for the sling. The technique for making the cover 14 will depend on the material from which it is made. It may be woven or extruded in a seamless tube. Alternately, the cover 14 may be formed by adjoining the long edges of an elongate strip of material by some suitable means, such as stitching, seaming, stapling, gluing, hot melt adhesive and the like.
[0016] The material for forming the cover 14 preferably is a transparent material through which the condition of substantially the entire core is viewable. As used herein, “transparent” means any condition which permits the core fibers to be visually inspected therethrough. Thus, “transparent,” as applied to the cover 14 , includes a fabric formed of threads or fibers that are clear or transparent so that, no matter how tightly woven or integrated, the core yarns 12 are visible through it, as is depicted in FIG. 2 .
[0017] In addition, “transparent” encompasses an otherwise opaque material or fabric that is so porous or loosely woven that the condition of the core fibers can be seen through the voids in the weave. Still further, “transparent” includes a condition that permits fluorescent material, when exposed to ultraviolet light, to be seen through the cover.
[0018] One preferred material for the cover 14 is netting of the type used for insect screens, such as that sold as “no-thrips” insect screen by BioQuip Products, Inc. (Rancho Dominguez, Calif.). This netting material is made of high tensile-strength monofilaments. It is UV resistant and stabilized, and lightweight. The mesh size 81×81 has a hole opening size of 0.0059×0.0059, a thread size of 0.15 mm, light transmission of 66%, and a weight of 0.216 lbs./sq. yd.
[0019] The diameter and circumference of the roundsling 10 may vary depending on the intended uses. The roundsling 10 may also include a label (not shown) showing the manufacturer, the code or stock number, load capacities, and core and cover materials, as is presently required by ASME standards.
[0020] Now it will be appreciated that the roundsling 10 of the present invention offers advantages not heretofore available in synthetic roundslings. The transparent cover 14 , in whatever form it takes, allows substantially the entire core 12 to be visually inspected. In the preferred embodiment, where the cover 14 is formed of clear or translucent fabric, the entire length and circumference of the core 12 can be visualized without opening, turning or otherwise manipulating the cover. In addition, the core 12 can be seen at all times—before, during and after each use. In this way, the sling 10 can be removed from service immediately upon exhibiting any change or damage that compromises its safe use.
[0021] Changes can be made in the combination and arrangement of the various parts and elements described herein without departing from the spirit and scope of the invention as defined in the following claims.
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A roundsling with a fully inspectable core. The roundsling comprises synthetic, non-metallic core yarns contained in a tubular cover that is transparent. Because the cover is transparent, the load-bearing core fibers are entirely, frequently and directly visible before, during and after use.
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FIELD OF THE INVENTION
The present invention relates to a four-cycle engine and more particularly to a valve moving mechanism for driving intake and exhaust valves of a four-cycle engine.
BACKGROUND OF THE INVENTION
Ordinarily, in a four-cycle engine mounted upon a vehicle such as, for example, an automobile or motorcycle, intake and exhaust valves are disposed above a combustion chamber and are driven by means of a valve moving mechanism.
The valve moving mechanism has a cam shaft interlocked with a crank shaft of the engine and the intake and exhaust valves are moved upwardly and downwardly in accordance with predetermined timing patterns by means of cams formed upon the cam shaft.
It is desirable for a four-cycle engine to have a large output throughout a wide range of engine speed including low and middle-high speed ranges, that is, to have a wide-range power band.
In conventional valve moving mechanisms, however, the valve opening-closing timing patterns and the valve lifting movements are fixed and the output characteristics are thereby restricted so that the output of the engine peaks within a particular engine speed range. Therefore, it is necessary to select one of the following two inconsistent patterns of engine output characteristics, one being based upon importance of achieving the engine output characteristics within a low speed range and the other being based upon the importance of achieving the engine output characteristics within a middle-high speed range.
OBJECT OF THE INVENTION
An object of the present invention is to substantially eliminate the defects or drawbacks encountered in connection with the conventional technology described above and to provide a valve moving mechanism particularly for a four-cycle engine of a vehicle which is capable of improving the output characteristics of the engine within a wide range of engine speed including low and middle-high speed ranges.
SUMMARY OF THE INVENTION
This and other objects can be achieved according to the present invention by providing a valve moving mechanism for a four-cycle engine of a vehicle which is operatively connected to a crank shaft of the engine and which is adapted to move the intake and exhaust valves of the engine, comprising a cam shaft operatively connected to the crank shaft, cam means including first, second and third cams mounted upon the cam shaft, the second and third cams having outer profiles different from that of the first cam disposed between the second and third cams, a rocker shaft supported so as to be pivotable about the longitudinal axis thereof, rocker arm means mounted so as to be pivotable about the rocker shaft axis and including first, second and third rocker arms driven in engagement with the first, second and third cams, respectively, the rocker arm means being operatively connected to the intake and exhaust valves, the first, second and third rocker arms having supporting bases mounted upon the rocker shaft, and bush means mounted upon the rocker shaft and being selectively in engagement with the first, second and third rocker arms and having an axis eccentric with respect to the axis of the rocker shaft.
In accordance with preferred embodiments of the present invention, and in accordance with one aspect thereof, the first rocker arm is provided with divergent front ends directly abutting against top portions of the intake and exhaust valves, the second and third rocker arms are provided with front ends abutting against the divergent front ends of the first rocker arm and the bush means is operatively engaged with the supporting bases of the second and third rocker arms.
In this embodiment, the supporting bases of the second and third rocker arms are moved downwardly relative to the supporting base of the first rocker arm as a result of the rotation of the large-diameter eccentric portions in response to pivotal rotation of the rocker shaft through means of a predetermined angle so that the abutment of the second and third rocker arms against the second and third cams is cancelled while the first rocker arm is brought into abutment against the first so as to move the valves by means of the first cam, and the supporting bases of the second and third rocker arms are moved upwardly relative to the supporting base of the first rocker arm as a result of the rotation of the large-diameter eccentric portions in response to pivotal rotation of the rocker shaft through means of a predetermined angle so that the abutment of the first rocker arm against the first cam is cancelled while the second and third rocker arms are brought into abutment against the second and third cams so as to move the valves by means of the second and third cams.
In accordance with another aspect of the present invention, the second and third rocker arms are provided with front ends directly abutting top portions of the intake and exhaust valves, the first rocker arm is provided with divergent front ends abutting against the front ends of the second and third rocker arms and the bush means is operatively engaged with the supporting bases of the second and third rocker arms.
In this embodiment, the supporting bases of the second and third rocker arms are moved downwardly relative to the supporting base of the first rocker arm as a result of the rotation of the large-diameter eccentric portions in response to the pivotal rotation of the rocker shaft through means of a predetermined angle so that the abutment of the second and third rocker arms against the second and third cams is cancelled while the first rocker arm is brought into abutment against the first cam so as to move the valves by means of the first cam, and the supporting bases of the second and third rocker arms are respectively moved upwardly relative to the supporting base of the first rocker arm as a result of the rotation of the large-diameter eccentric portions in response to pivotal rotation of the rocker shaft through means of a predetermined angle so that the abutment of the first rocker arm against the first cam is cancelled while the second and third rocker arms are respectively brought into abutment against the second and third cams so as to move the valves by means of the second and third cams.
In accordance with a further aspect of the present invention, the first rocker arm is provided with divergent front ends directly abutting top portions of the intake and exhaust valves, the second and third rocker arms are provided with front ends abutting the divergent front ends of the first rocker arm and the bush means is operatively engaged with the supporting base of the first rocker arm.
In accordance with this embodiment, the supporting base of the first rocker arm is moved downwardly relative to the supporting bases of the second and third rocker arms as a result of the rotation of the large-diameter eccentric portion in response to the pivotal rotation of the rocker shaft through means of a predetermined angle so that the abutment of the first rocker arm against the first cam is cancelled while the second and third rocker arms are brought into abutment against the second and third cams so as to move the valves by means of the second and third cams, and the supporting base of the first rocker arm is moved upwardly relative to the supporting bases of the second and third rocker arms as a result of the rotation of the large-diameter eccentric portion in response to the pivotal rotation of the rocker shaft through means of a predetermined angle so that the abutment of the second and third rocker arms against the second and third cams is cancelled while the first rocker arm is brought into abutment against the first cam so as to move the valves by means of the first cam.
In accordance with a still further aspect of the present invention, the second and third rocker arms are provided with front ends directly abutting top portions of the intake and exhaust valves, the first rocker arm is provided with divergent front ends abutting the front ends of the second and third rocker arms and the bush means is operatively engaged with the supporting base of the first rocker arm.
In accordance with this embodiment, the supporting base of the first rocker arm is moved downwardly relative to the supporting bases of the second and third rocker arms as a result of the rotation of the large-diameter eccentric portion in response to the pivotal rotation of the rocker shaft through means of a predetermined angle so that the abutment of the first rocker arm against the first cam is cancelled while the second and third rocker arms are brought into abutment against the second and third cams so as to move the valves by means of the second and third cams, and the supporting base of the first rocker arm is moved upwardly relative to the supporting bases of the second and third rocker arms as a result of the rotation of the large-diameter eccentric portion in response to the pivotal rotation of the rocker shaft through means of a predetermined angle so that the abutment of the second and third rocker arms against the second and third cams is cancelled while the first rocker arm is brought into abutment against the first cam so as to move the valves by means of the first cam.
The mechanism according to the present invention has two types of valve driving cams having different profiles. One of these cams to be used can be selected by selectively rotating the rocker shaft through means of a predetermined angle.
If one of these cams has a profile suitable for operation within a low engine speed range while the other has a profile suitable for operation within a middle-high engine speed range, the output from the four-cycle engine can be improved over a wide revolutionary speed range covering both the low and middle-high speed ranges.
In accordance with the valve moving mechanism of the present invention, the selection of the cams is effected by pivotably rotating the aforenoted large-diameter eccentric portions, and therefore there is no risk of application of large stresses to the respective portions, thereby enabling each cam to be smoothly selected.
Various other objects, features, and attendant advantages of the present invention will become better understood from the following detailed description, when considered in connection with the accompanying drawings, in which like reference characters designate like or corresponding parts throughout the several views, and wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective view of an embodiment comprising a valve moving mechanism for a four-cycle engine constructed in accordance with first aspect of the present invention;
FIG. 2 is a plan view of the valve moving mechanism of the aforenoted embodiment;
FIGS. 3 and 4 are moving state diagrams showing the operation of the valve moving mechanism of the aforenoted embodiment;
FIG. 5 is a plan view of another embodiment of a valve moving mechanism constructed in accordance with a second aspect of the present invention;
FIGS. 6 and 7 are moving state diagrams showing the operation of the embodiment shown in FIG. 5;
FIG. 8 is a plan view of still another embodiment of a valve moving mechanism constructed in accordance with a third aspect of the present invention;
FIGS. 9 and 10 are moving state diagrams showing the operation of the embodiment shown in FIG. 8;
FIG. 11 is a plan view of a further embodiment of a valve moving mechanism constructed in accordance with a fourth aspect of the present invention;
FIGS. 12 and 13 are moving state diagrams showing the operation of the embodiment shown in FIG. 11; and
FIGS. 14 to 16 are graphs representing the valve lift characteristics of the various components as utilized within the various embodiments of the invention, respectively.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The various embodiments of the present invention will now be described below with reference to the accompanying drawings.
FIG. 1 schematically shows essential portions of a valve moving mechanism constructed according to the present invention.
Two valve moving mechanisms of this type are respectively provided upon the intake and exhaust sides of each cylinder of the engine. Accordingly, valves 1 and 2 shown in FIG. 1 are provided so as to effect intake or exhaust, accordingly, in connection with an intake valve and an exhaust valve.
This embodiment has a cam shaft 6 operatively connected to a crank shaft C of an engine and includes a cam 3 and cams 4 and 5 respectively positioned upon opposite sides of the cam 3, rocker arms 7, 8 and 9 respectively disposed below the cams 3, 4, and 5, and a rocker shaft 11 around which supporting bases 7a, 8a and 9a of the rocker arms 7, 8 and 9 are disposed and which is rotatably supported by means of unillustrated bearings.
The rocker arm 7 has two end portions divergent in two directions, and two diverging ends 7b respectively abut against stem head portions of the valves 1 and 2 for closing the combustion chamber of the unillustrated engine cylinder.
The supporting base 8a of the rocker arm 8 is pivotably mounted upon the rocker shaft 11 by means of a bush 12 having a diameter larger than the rocker shaft and interposed therebetween.
The axis of the bush 12 is eccentric from the axis of the rocker shaft 11, and the bush 12 is fixed to the shaft 11 by means of an unillustrated pin. The bush 12 functions as an eccentric large-diameter portion of the rocker shaft 11.
As shown in FIG. 2, the supporting base 9a of the rocker arm 9 is also pivotably mounted upon the rocker shaft 11 by means of a bush 13 interposed therebetween. The bush 13 has the same shape and is eccentric in the same direction as is the bush 12.
Lower surfaces of distal end portions of the rocker arms 8 and 9 abut against the diverging distal end portions 7b of the rocker arm 7. If a cam follower surface 7c of the rocker arm 7 is depressed so as to move the distal end portions 7b downwardly, the distal end portions of the rocker arms 8 and 9 also move downwardly by following the downward movement of the distal end portions 7b.
If cam follower surfaces 8c and 9c of the rocker arms 8 and 9 are depressed, the distal end portions of the arms 8 and 9 depress the distal end portions 7b of the rocker arm 7, thereby forcibly moving the distal end portions 7b downwardly.
With respect to the cams 3, 4, and 5, the cams 4 and 5 have identical profiles, and the cam 3 has a profile different from that of the cams 4 and 5.
The profile of the cam 3 is determined so as to obtain a valve lift movement or operation suitable for operation of the engine within a low speed range. The profile of the cams 4 and 5 is determined so as to obtain a valve lift movement or operation suitable for engine operation within a middle-high speed range.
These valve lift movements correspond to stroke lengths of the valves 1 and 2. In FIG. 14 the symbol la represents the valve lift based upon the drive of the cam 3 and the symbol lb represents the valve lift based upon the drive of the cams 4 and 5.
As is apparent from FIG. 14, the cam profiles are determined so that the valve lift obtained by means of the cams 4 and 5 is larger than that obtained by means of the cam 3.
The operation of this embodiment will now be described hereunder.
An engine revolution sensor 17 detects the engine speed and outputs a signal corresponding to the engine speed.
A motor drive circuit 18 shown in FIG. 1 determines by comparison with respect to predetermined speed values whether the engine speed represented by means of the value of the signal output from the sensor 17 is within the low speed range or within the middle-high speed range. If the engine speed is within the low speed range, a motor 15 is driven so as to rotate the rocker shaft 11 so that the eccentric bushes 12 and 13 are disposed at their angular positions shown in FIG. 3. If the engine speed is within the middle-high speed range, the motor 15 is driven so as to rotate the rocker shaft 11 so that the eccentric bushes 12 and 13 are disposed at their angular positions shown in FIG. 4.
In the state shown in FIG. 3, portions 12a and 13a of the eccentric bushes 12 and 13 are disposed at lower positions such that the supporting bases 8a and 9a of the rocker arms 8 and 9 are moved downwardly relative to the supporting base 7a of the rocker arm 7.
A gap t is thereby formed between the peripheral surfaces of the cams 4 and 5 and the cam follower surfaces 8c and 9c of the rocker arms 8 and 9. Consequently, the cams 4 and 5 rotate without encountering the rocker arms 8 and 9.
On the other hand, since the rocker arm 7 is always lifted by being swung upwardly about the axis of the rocker shaft 11 by means of the biasing force of a valve spring 16, the cam follower surface 7c of the rocker arm 7 abuts against the peripheral surface of the cam 3. As a result, as the cam shaft 6 rotates, the valves 1 and 2 are moved upwardly and downwardly in accordance with the lift characteristics A shown in FIG. 14. That is, the valves 1 and 2 are moved so as to open or close the combustion chamber in accordance with valve lift characteristics suitable for low engine speed range operation.
In the state shown in FIG. 4, the portions 12a and 13a of the eccentric bushes 12 and 13 are disposed at the upper positions such that the supporting bases 8a and 9a of the rocker arms 8 and 9 are moved upwardly relative to the supporting base 7a of the rocker arm 7, whereby the cam follower surfaces 8c and 9c of the rocker arms 8 and 9 respectively abut against the peripheral surfaces of the cams 4 and 5.
As shown in FIG. 14, the cams 4 and 5 are formed so as to have a larger cam lift movement in comparison with that of the cam 3. Consequently, in the state shown in FIG. 4, as the cam shaft 6 is rotated, the cam 3 rotates freely without encountering the rocker arm 7, while the cams 4 and 5 respectively operate the rocker arm 7 through means of the rocker arms 8 and 9.
As a result, the valves 1 and 2 are moved so as to open or close the combustion chamber the particular engine cylinder in accordance with the noted valve lift movements suitable for the middle-high engine speed range, that is in accordance with the lift characteristic B shown in FIG. 14.
In the above-described embodiment, the profiles of the cams 4 and 5 may be changed so as to obtain valve lift characteristics B' and B" such as those shown in FIGS. 15 and 16 during operation within the middle-high engine speed range.
It is further noted that one of the rocker arms 8 and 9 shown in FIG. 2 may be omitted. In such a case, however, the depressing force cannot be uniformly applied to the extreme end portions of the rocker arms 7 and, therefore, is a risk that a difference between the lift movements of the valves 1 and 2 will occur.
During high-speed rotation of the cams 4 and 5, there is a risk that the rocker arms 8 and 9 move freely and generate noise.
In order to avoid this problem, a suitable spring means may be used so as to bias the rocker arms 8 and 9 in the counterclockwise direction as viewed in FIG. 3 with respect to the rocker arm 7. The lower surfaces of the distal end portions of the rocker arms 8 and 9 can thereby be forcibly made to abut against the distal end portions 7b of the rocker arm 7, thereby enabling the rocker arms 8 and 9 to follow the movement of the rocker arm 7. It is thus possible to prevent the occurrence of noise due to the uncontrolled movement of the rocker arms 8 and 9.
FIG. 5 shows another embodiment of the present invention. Components of this embodiment identical to those shown in connection with the embodiment of FIG. 1 are indicated by means of the same reference numerals, and corresponding components are indicated by means of corresponding numerals with primes.
In this embodiment, as shown in FIG. 6, the distal end portions of rocker arms 8' and 9' directly abut against stem head portions of valves 1 and 2, while the diverging distal end portions 7b' of the rocker arm 7' respectively abut against upper surfaces of the distal end portions of the rocker arms 8' and 9'.
FIG. 6 shows the state in which the portions 12a and 13a of eccentric bushes 12 and 13 are disposed downwardly, while FIG. 7 shows the state in which the portions 12a and 13a of the eccentric bushes 12 and 13 are disposed upwardly.
The states shown in FIGS. 6 and 7 are predetermined by controlling the rotation of the rocker shaft 11 by means of the motor 15 shown in FIG. 1.
When the bushes 12 and 13 are at the rotational position shown in FIG. 6, the cam follower surface 7c' of the rocker arm 7' abuts against the cam 3 while cam follower surfaces 8c' and 9c' of the rocker arms 8' and 9' are spaced apart from the cams 4 and 5.
The motion of the rocker arm 7' caused by means of the rotation of the cam 3 is transmitted to the valves 1 and 2 through means of the rocker arms 8' and 9', respectively, thereby moving the valves 1 and 2 for valve opening or closing operations in accordance with the characteristic curve A shown in FIG. 14.
On the other hand, when the bushes 12 and 13 are disposed at the rotational position shown in FIG. 7, the cam follower surface 7c' of the rocker arm 7' is spaced apart from the cam 3 while the cam follower surfaces 8c' and 9c' of the rocker arms 8' and 9' abut against the cams 4 and 5, respectively.
Consequently, the motions of the rocker arms 8' and 9' caused by means of the rotation of the cams 4 and 5 are directly transmitted to the valves 1 and 2, respectively, thereby moving the valves 1 and 2 for valve opening or closing operations in accordance with the characteristic curve B shown in FIG. 14. At this time, the rocker arm 7' moves under the influence of its own weight so as to follow the movements of the rocker arms 8' and 9'.
In this embodiment, in the state shown in FIG. 7, there is a risk that the rocker arm 7' will move freely and thereby generate noise. It is therefore preferable to bias the rocker arm 7' in the counterclockwise direction by means of a suitable spring means mounted upon the rocker arms 8' or 9'. The distal end portion of the arm 7' can therefore be pressed against the distal end portions of the arms 8' and 9', thereby enabling the arm 7' to move in accordance with the movements of the arms 8' and 9'. It is therefore possible to prevent the occurrence of noise due to the free movement of the arm 7'.
FIG. 8 shows still another embodiment of the present invention.
This embodiment comprises a cam shaft 106 having a cam 104 and cams 103B and 103A respectively positioned upon opposite sides of the cam 104, rocker arms 107, 108 and 109 respectively disposed below the cams 104, 103A and 103B, and a rocker shaft 111 around which supporting bases 107a, 108a and 109a of the rocker arms 107, 108 and 109 are disposed and which is rotatably supported by means of unillustrated bearings.
The cam 104 has the same cam profile as that of the cam 4 shown in FIG. 1 and the cams 103A and 103B have the same cam profile as that of the cam 3 shown in FIG. 1.
The rocker arm 107 has two distal end portions diverging in two directions, as in the case of the rocker arm 7 shown in FIG. 1, and the diverging ends 107b respectively abut against stem head portions of the valves 101 and 102.
The supporting base 107a of the rocker arm 107 is rotatably mounted upon the rocker shaft 111 with a bush 112, having a diameter larger than that of the rocker shaft 111, interposed therebetween.
The bush 112 has the same contour as that of the bush 12 shown in FIG. 1 and is fixed to the shaft 111 by means of a pin or the like so as to have an eccentricity relative to the axis of the rocker shaft 111, as shown in FIG. 9.
The bush 112 therefore functions as a large-diameter eccentric portion of the cam shaft 111.
The supporting bases 108a and 109a of the rocker arms 108 and 109 are rotatably supported upon portions of the rocker shaft 111 other than the large-diameter eccentric portion of the same. Lower surfaces of distal end portions of the rocker arms 108 and 109 respectively abut against the distal end portions 107b of the rocker arm 107.
The operation of this embodiment will now be described below.
The rocker shaft 111 is rotated through means of a predetermined angle by means of the motor 15 shown in FIG. 1. That is, if the engine speed detected by means of the sensor 17 shown in within FIG. 1 is in a low speed range, the rocker shaft 111 is rotated so that the eccentric portion 112a of the eccentric bush 112 is disposed downwardly as shown in FIG. 9. Alternatively, if the engine speed is within a middle-high speed range, the rocker shaft 111 is rotated so that the portion 112a of the eccentric bush 112 is disposed upwardly as shown in FIG. 10.
In the state shown in FIG. 9, the portion 112a of the eccentric bush 112 is at its lower position such that the supporting base 107a of the rocker arm 107 is moved downwardly relative to the supporting bases 108a and 109a of the rocker arms 108 and 109.
Consequently, the abutment of the cam follower surface 107c of the rocker arm 107 against the peripheral surface of the cam 104 is cancelled, thereby permitting the cam 104 to rotate freely without encountering the rocker arm 107 or its cam follower surface 107a.
On the other hand, since the rocker arms 108 and 109 are always lifted by being swung upwardly about the axis of the rocker shaft 111 by means of the biasing force of a valve spring 116, cam follower surfaces 108c and 109c of the rocker arms 108 and 109 abut against the peripheral surfaces of the cams 103A and 103B. Consequently, as the cam shaft 106 rotates, the valves 101 and 102 are moved upwardly and downwardly in accordance with the lift characteristic curve A shown in FIG. 14. That is, the valves 101 and 102 are moved so as to open or close the combustion chamber of the particular cylinder in accordance with the valve lift operations suitable for low engine speed range operation.
In the state shown in FIG. 10, the portion 112a of the eccentric bush 112 is at an upper position such that the supporting base 107a of the rocker arm 107 is moved upwardly relative to the supporting bases 108a and 109a of the rocker arms 108 and 109. The cam follower surface 107c of the rocker arm 107 is thereby brought into abutment against the peripheral surface of the cam 104.
Consequently, as the cam shaft 106 rotates, the cams 103A and 103B rotate freely without encountering the cam follower surfaces 108c and 109c of the rocker arms 108 and 109, respectively, while the cam 104 drives the rocker arm 107 as a result of encountering the cam follower surface 107c thereof.
As a result, the valves 101 and 102 are moved so as to open or close the combustion chamber of the particular cylinder in accordance with the lift characteristic curve B shown in FIG. 14, that is, in accordance with the valve lift movements suitable for the middle-high engine speed range operation.
In connection with the above-described embodiment, one of the rocker arms 108 and 109 may be omitted. In such a case, however, the depressing force cannot be uniformly applied to both distal end portions 107b of the rocker arms 107, and therefore there is a risk that a difference between the lift movements of the valves 101 and 102 may occur.
In the state shown in FIG. 10, there is a risk that the rocker arms 108 and 109 will move freely and thereby generate noise. In this embodiment, therefore, a suitable spring means is used so as to bias the distal end portions of the rocker arms 108 and 109 toward the distal end portions 107b of the rocker arm 107, thereby preventing the occurrence of noise due to the free movement of the rocker arms 108 and 109.
FIG. 11 discloses a further embodiment of the present invention. Components of this embodiment identical to those shown in connection with the embodiment of FIG. 8 are indicated by means of the same reference numerals and corresponding components are indicated by means of corresponding numerals with primes.
In this embodiment, as shown in FIG. 12, distal end portions of rocker arms 108' and 109' directly abut against stem head portions of valves 101 and 102, while diverging distal end portions 107b' of a rocker arm 107' respectively abut against upper surfaces of the distal end portions of the rocker arms 108' and 109'.
FIG. 12 shows a state in which an eccentric portion 112a of the eccentric bush 112 is disposed downwardly and FIG. 13 shows a state in which the eccentric portion 112 is disposed downwardly.
The states shown in FIGS. 12 and 13 are predetermined by controlling the rotation of the rocker shaft 111 by means of the motor 15 shown in FIG. 1.
When the bush 112 is disposed at the rotational position shown in FIG. 12, cam follower surfaces 108c' and 109c' of the rocker arms 108' and 109' abut against the cams 103A' and 103B' while the cam follower surface 107c' of the rocker arm 107' is spaced apart from the cam 104.
Consequently, as the cams 103A' and 103B' are rotated, the motions of the rocker arms 108' and 109' are transmitted directly to the valves 101 and 102, respectively, thereby effecting lift movements of the valves 101 and 102 in accordance with the characteristic curve A shown in FIG. 14.
At this time, the rocker arm 107' moves under the influence of its own weight so as to follow the movements of the rocker arms 108' and 109'.
When the bush 112 is disposed at the rotational position shown in FIG. 13, the cam follower surfaces 108c' and 109c' of the rocker arms 108' and 109' are spaced apart from the cams 103A' and 103B' while the cam follower surface 107c' of the rocker arm 107' abuts against the cam 104.
Consequently, the motion of the rocker arm 107' caused by means of the rotation of the cam 104 is transmitted to the valves 101 and 102 through means of the distal end portions of the rocker arms 108' and 109', respectively, thereby effecting lift movements of the valves 101 and 102 in accordance with the characteristic curve B shown in FIG. 14. In the state shown in FIG. 12, there is a risk of that the rocker arm 107' will move freely. In this embodiment, therefore, a suitable spring means (not shown) is used so as to bias the distal end portions 107b' of the rocker arm 107' against the distal end portions of the rocker arms 108' and 109', thereby preventing the occurrence of noise due to the free movement of the rocker arm 107'.
In the embodiment shown in FIGS. 8 and 11, the profile of the cam 104 may be changed so as to enable the valves 101 and 102 to be lifted in accordance with the lift characteristic curves B' and B" shown in FIGS. 15 and 16 during operation within the middle-high engine speed range.
In each of the above-described embodiments, the motor 15 shown in FIG. 1 is used as a rotational drive source for the rocker shafts. Alternatively, a hydraulic or pneumatic cylinder may be used as the drive source. In such a case, a rack and a pinion are used as a power transmitting means.
Obviously, 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 present invention may be practiced otherwise than as specifically described herein.
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A valve moving mechanism for a four-cycle engine of a vehicle is operatively connected to a crank shaft of the engine and is adapted to move intake and exhaust valves. A cam shaft of the valve moving mechanism is operatively connected to the crank shaft and cam means including first, second and third cams is mounted upon the cam shaft, the second and third cams having outer profiles different from that of the first cam disposed between the second and third cams. Rocker arm means are mounted so as to be rotatable upon the rocker shaft which is rotatably mounted and includes first, second and third rocker arms driven in engagement with the first, second and third cams, respectively. The rocker arm means is operatively connected to the intake and exhaust valves, the first, second and third rocker arms having supporting bases mounted upon the rocker shaft. Bush means are mounted upon the rocker shaft so as to be selectively in engagement with the first, second and third rocker arms and has an axis eccentric with respect to the axis of the rocker shaft.
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BACKGROUND OF THE INVENTION
This application is a continuation in part of U.S. Patent Application S/N 411,868 filed Nov. 1, 1973, now abandoned.
Combustion systems for gas turbines are presently available which minimize the emission of carbon monoxide and unburned hydrocarbons. However, attempts to provide for low nitrous oxide emission in gas turbine engines have proven difficult to achieve mainly because of the high reaction temperatures utilized in the engines. It has been determined that for fuel-lean and chemically correct mixtures of hydrogen and air, nitrous oxides are formed in post flame combustion gases and its reaction rate is greatly dependent upon the reaction temperature and the time that the mixture is held at this temperature. That is, the higher the reaction temperature, the faster the reaction time and, accordingly, the formation of more undesirable nitrous oxide. For this reason it has proven difficult to provide gas turbine engines with the lowest possible nitrous oxide emission in order to meet present or future exhaust emission standards.
Examples of prior art gas turbine engine combustion systems can be found in the following U.S. Pat. Nos.: 2,458,066 to Farkas et al; 3,541,790 to Kellett; and 3,584,459 to Amann. Of particular interest is U.S. Pat. No. 2,622,395 to Bowden which also describes combustion apparatus; and U.S. Pat. No. 3,656,298 to Wade and U.S. Pat. No. 3,705,492 to Vickers, both of which describe combustion apparatus minimizing the formation of oxides of nitrogen.
SUMMARY OF THE INVENTION
The invention disclosed herein overcomes the disadvantages of the prior art devices described above by providing a combustor having two separate chambers. In the first chamber, fuel is vaporized and mixed with primary air from the compressor which has been precooled before being directed to the combustor. The air-fuel mixture from the mixing chamber is forced by pressure differential through a porous ceramic plate into the primary burning zone in the second chamber of the combustor. The porous plate acts as a mixing device for mixing the air-fuel mixture uniformly and, in the lower combustion chamber, acts as a flame holder to maintain the primary burning zone up near the hot lower surface of the disc to speed reaction. Secondary air which has been passed through a recuperator for additional heating is introduced into the lower combustion chamber. The mixture in the primary zone is a fuel rich mixture and, being fully mixed with primary air, burns rapidly in the primary zone providing short flame dwell times at high combustion temperatures resulting in lower nitrus oxide generation. This mixture then flows into the secondary zone where diluent air is added to create a fuel lean mixture providing for low hydrocarbon content in the exhaust emissions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic showing of the combustion system for a gas turbine engine embodying the present invention;
FIG. 2 is a vertical cross sectional view of exemplary apparatus embodying the present invention;
FIG. 3 is a bottom view of the disc of FIG. 2;
FIG. 4 is a cross sectional view of the disc;
FIG. 5 is a partial showing of the combustion system of FIG. 1 including a modification;
FIG. 6 is a sectional view of the combustor taken along line 6--6 of FIG. 2; and
FIG. 7 shows a second embodiment of the porous disc.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The drawings, and in particular FIG. 1, illustrate a gas turbine engine 10 including an air compressor 12 which discharges compressed air through a conduit 14. A branch conduit 16 conveys a portion of the compressed air, which is primary air, through an intercooler 18 to the engine combustor 20. A flame tube 22, best illustrated in FIG. 2, is positioned within a casing 24, as by means of an annular ring member 26. The ring 26 is suitably fastened as by welding to the casing 24 and tube 22 to form an upper chamber 27 surrounding the dome 28 of the flame tube and an annular lower chamber 30 surrounding the lower portion of the tube. The flame tube 22 is divided into an upper pre-mix or primary chamber 32 and a lower combustion chamber 34 by a porous ceramic disc 36 suitably positioned within the tube 22 as by bonding. The disc 36 can be of circular shape. The primary air from the branch conduit 16 is conveyed into the upper chamber 26 and then into the pre-mix chamber 32 of the tube 22 by openings 38 wherein it is mixed with fuel injected into the pre-mix chamber 32 by any conventional means as by an atomizer nozzle 40 and an additional air assist apparatus 42 adapted to be connected to the compressor 12, as shown in FIG. 2.
The mixed air-fuel impinges on the upper surface of the porous ceramic disc 36, which can be fashioned from high temperature ceramics such as silicon nitrite, silicon carbide, or the like. The disc 36 is permeable to a mixture of fuel and air. The fuel droplets, mixed with the primary air, are vaporized within the pores of the heated ceramic disc 36 and enter the lower chamber 34 as a uniform fuel rich mixture of air and fuel vapor for combustion as by the ignitor 44 near the lower surface of the ceramic disc 36. The radiation of the flame provides the heat to maintain the disc 36 at an elevated temperature to insure fuel vaporization. The ceramic disc 36 within the flame tube not only provides uniformity to the air-fuel vapor mixture to thus reduce the high local reaction temperature, but also acts as a flame holder to provide stable combustion for the lean primary fuel-air mixture from chamber 32 to lower the flame temperature in chamber 34.
The lower surface of ceramic disc 36 is further provided with a coating 46 of material such as platinum, or the like, best shown in FIG. 3. The platinum can be lightly sprayed on the surface so as not to destroy the porosity of the disc. The platinum acts as a catalyst to provide a speeding up of surface combustion to shorten the fuel residence time in the primary chamber 32 which minimizes the time exposure of the post flame gases at elevated temperatures resulting in minimal formation nitrous oxides.
As is illustrated in FIGS. 3 and 6, the ceramic disc may be provided with a plurality of holes near its outer edge which allow a portion of the air-fuel mixture from chamber 32 to flow through these openings without passing through the disc pores. This vapor is forced into the lower chamber and aids in recirculation of the primary burning mixture in chamber 34 to maintain it against the lower surface of the disc 36. As shown in FIG. 7, the holes 47 in the disc may be eliminated and the disc 36' formed with a varying density across its diameter. As illustrated in FIG. 6, the disc has a high density in the center and with the porosity becoming more open near the edge. Thus a greater amount of the fuel-air mixture from the upper premix chamber will flow through the edge portion than flows through the center, again resulting in substantial recirculation of the primary burning mixture in the lower chamber to maintain the mixture near the lower surface of the disc.
In order to minimize excessive formation of nitric oxide during start-up of the gas turbine 10, as shown in FIG. 4, the ceramic disc 36 has embedded therein electric heating wires 48 connected to a suitable electrical power source 49 for preheating the disc 36 prior to the admission of fuel to the combustion chamber 34. Once combustion has been initiated, the disc will be maintained above the vaporization temperature by the heat of combustion.
Referring again to FIG. 1, another branch conduit 50 conveys the rest of the compressed air, which is secondary air, through a heat exchanger apparatus 52 to the lower chamber 30 and then through openings 54 in the flame liner 22 to the lower part of the combustion chamber 34. The combustion products from the combustion apparatus 20 are discharged from the chamber 34 through conduit 56 into a first or high pressure turbine 58. The turbine 58 drives the compressor 12 through the shaft 60.
The exhaust from the turbine 58 is supplied to a second or low pressure turbine 62 through the combustion products conduit 64. The turbine 62 drives a shaft 66 to which may be connected any desired load (not illustrated). The low pressure exhaust from the turbine 62 is conveyed through conduit 68 to the heat exchanger 52 and then to exhaust to atmosphere through conduit 70. The heat exchanger 52 can be of any suitable type, as for example a recuperator.
Conveying primary air directly from the compressor 12 through the conduit 16 to the primary chamber 32 without adding heat from the heat exchanger 52 helps to maintain the lowest attainable reaction temperature in the combustion chamber 34. It is appreciated that this somewhat increases the specific fuel consumption, which is undesirable, but at the same time results in increased effectiveness of the heat exchanger 52, because only the air flow to the air side of the heat exchanger 52 is decreased by the amount of primary air used in the pre-mix chamber 32, while the gas flow to the gas side of the heat exchanger 52 is not decreased. This results in a higher air temperature of the secondary air which is introduced into the combustion chamber 34 downstream of the reaction zone for quenching or cooling the combustion products.
Provision of the intercooler 18 between the compressor 12 and the pre-mix chamber 32 inlet serves as yet another means for controlling the primary air temperature to further minimize or lower the formation of nitric oxide emission. To this end, the intercooler 18, as shown in FIG. 2, is provided with an open chamber 72 having positioned therein a plurality of tubes 74 through which the compressed air is forced first to the chamber 26 and then to the pre-mix chamber 32. Cooling of the tubes 74 and compressed air therein is accomplished by means of a fan 76 capable of rotation by a variable speed motor (not shown) and passing ambient air over the tubes. The heat removed from the compressed air can be utilized as clean heat for personnel in the vehicle (not shown).
The operation of the device may be further explained by analyzing the pressure distribution through the system. As is noted above, the combuster casing is divided into two distinct separate chambers by the annular wall member 26 as shown in FIGS. 1 and 6. This is necessary in order to ensure that the fuel-air mixture from the pre-mix chamber passes through the plate rather than around it. In addition, the use of the recuperator for heating the secondary combustion air is highly desirable to increase fuel efficiency. There is however a second advantage in including this recuperator in the system. If it is assumed that the compressor of a gas turbine will raise the pressure of the inlet air from atmospheric pressure by a ratio of 6:1, the output from the compressor in conduit 16 will be at approximately 88.2 lbs per square inch. A typical heat exchanger pressure loss would be in the neighborhood of 4% which would amount to approximately 3.5 p.s.i., and the pressure drop across the flame liner surface is typically 3% which would be an additional 2.65 p.s.i. The air, as it enters the diluent or combustion chamber 34 of the liner after the drop of the heat exchanger and liner will be at a pressure of approximately 82 p.s.i. The primary air from the compressor will enter the upper chamber 32 of the casing at the compressor discharge pressure of 88.2 p.s.i. Allowing for the 3% drop across the flame liner the pressure in the air-fuel mixture chamber will be at approximately 86.6 p.s.i. Thus by separating both the casing and the liner into separate chambers as defined in the claims of the application there is provided across the porous disc 36 a pressure differential of about 4.6 p.s.i. This pressure differential is required to force all of the fuel-air mixture through the disc so that it will be mixed and vaporized before entering the combustion zone in the lower portion of the liner. Thus it can be seen that the inclusion of the recuperator and the wall creating two separate chambers aid in achieving a proper pressure profile in the system.
As mentioned above, in the system of FIG. 1 all the primary air bypasses the recuperator 52, which results in a penalty in fuel consumption. Also in many instances, the exhaust emission requirements can be satisfied if only a portion of the primary air bypasses the recuperator 52. Accordingly, in some applications a regulating valve 80 is installed in a line 82 which connects the primary air line 16 with the secondary air line 50, as shown in FIG. 5. The valve 80 meters heated secondary air to the primary air thus modulating or regulating the temperature of the primary air. In its simplest form, the valve 80 can be a fixed orifice valve.
While a specific embodiment of the invention has been illustrated and described, it is to be understood that it is provided by way of example only and that the invention is not to be construed as being limited thereto, but only by the proper scope of the following claims.
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Primary air to the fuel-air mixing chamber of a gas turbine engine is cooled to reduce generation of nitrous oxides. A porous disc separates the fuel-air mixture chamber from the combustion chamber and serves to uniformly mix the fuel and air to reduce the reaction temperature. A catalyst is sprayed on the disc surface in the combustion chamber to speed combustion. A heater embedded in the disc heats the disc and prevents excessive generation of nitrous oxides during the engine start-up. A metering valve can be used to regulate the temperature of the primary air by supplying heated secondary air to the primary air.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a thermal energy transfer system for cooling a structure which can easily be added to an existing Freon compression air conditioning system which will replicate the operation of a conventional condensing unit while using only energy which was previously stored in the system and which does not require modification of the components of the air conditioning system normally located within the structure being cooled.
2. Description of the Prior Art
Because the utility electrical industry has incorporated reduced electrical rates in off-peak hours when demand is low, the electrical consumer has found it advantageous to purchase and store air conditioning in the off-peak hours and use it during peak hours. There are many methods of storing and retrieving thermal energy in an insulated tank. All require an insulated tank that contains a substance in which the thermal energy is stored.
One method utilizes a liquid that simply stores the thermal energy by reducing the temperature of the liquid. For example, if this liquid is water, one pound of water stores approximately one BTU per degree of Fahrenheit temperature reduction. The energy is stored by removing heat from the liquid by various methods. The energy is recovered by circulating the cooled liquid into a heat exchanger during peak hours where it absorbs heat because of the low temperature of the liquid.
Another method of thermal energy storage involves the freezing of the liquid inside the insulated tank to its solid state by various methods. The heat stored per pound of liquid is much greater because of the change of state of the liquid to solid. If water is the liquid, one pound of water stores approximately 144 BTU's per degree of Fahrenheit temperature reduction, the phenomenon being referred to as the latent heat. The energy is recovered from storage by circulating a substance (sometimes the same melted liquid) through or around the cold solid transferring heat to the solid until it is all melted back to its liquid state.
Another method of thermal energy storage is a combination of the two previously described methods. Thermal energy is stored by transferring heat out of a liquid until a portion of the liquid solidifies to a solid state resulting in a slurry of solid particles floating in a liquid. Thermal energy is retrieved by circulating the liquid of the slurry to the area to be cooled where heat is added to the cool liquid. The heat is rejected to the particles of solid floating in the slurry.
Because of problems involved in creating the above slurry and thus storing thermal energy, another method has evolved which uses sealed spherical balls containing a liquid that changes to its solid state to store thermal energy. These balls are contained in a liquid that freezes at a much lower temperature than the liquid contained in the balls. Energy is stored by removing heat from the low temperature liquid until the liquid inside the balls changes to the solid state. Energy is recovered by circulating the low temperature liquid to the area to where heat is added and then rejected to the melting of the liquid inside the balls. U.S. Pat. No. 4,768,579, issued to Patry, is an example of this method.
All of these methods have advantages and disadvantages, depending upon the particular end applications, methods of storing and retrieving heat, and commercial considerations of tank size, tank location, etc. All of these methods retrieve the stored energy by circulating a liquid to transfer the heat removed from the air conditioned area to the tank containing the material in which thermal energy is stored.
It has long been recognized that using Freon for the conversion and transfer of thermal energy was beneficial because the conventional method of air conditioning could be used when required during off-peak hours. Past efforts for this method of conversion and storage of thermal energy always used a conventional condensing unit. Past efforts for this method always used a coil submerged in liquid contained in an insulated tank for the thermal energy conversion and storage. These submerged coils had Freon flow through them to freeze the liquid to its solid state for energy storage. The same coil was used for stored energy recovery by flowing Freon through the coil where it condensed to its liquid state, thus adding heat to the frozen liquid in the tank. This method of converting and storing thermal energy is known informally as the “ice on pipe” technique and is described in the American Society of Heating, Refrigeration and Air-Conditioning Engineers Handbook 1998–2001. When using Freon for “ice on pipe” thermal energy conversion and storage, the problem of Freon management becomes increasingly important. Because the coil in the tank is relatively large, it holds large amounts of Freon. The system as a whole has to operate in three different modes:
1. thermal energy storage—making ice; 2. thermal energy retrieval—air conditioning from ice; and 3. conventional air conditioning.
Each mode requires a different mass of Freon to be in circulation because of the size and use of the coil inside the storage tank. The solution to the problem of Freon management in “ice on pipe” storage systems has been cumbersome with a number of different solutions having been proposed over the years. At least the following issued U.S. Patents deal with this problem: U.S. Pat. No. 4,735,064 Fischer; U.S. Pat. No. 5,211,029 Dean et al; U.S. Pat. No. 4,916,916 Fischer; U.S. Pat. No. 5,255,526 Fischer; U.S. Pat. No. 5,647,225 Fischer; U.S. Pat. No. 5,467,812 Dean et al; U.S. Pat. No. 5,678,626 Dean et al; U.S. Pat. No. 5,682,752 Dean et al.
These solutions are complicated and eliminate the possibility of multiple air conditioning systems using a common storage tank. It is more expensive to provide multiple thermal energy tanks than to provide one tank of the combined volume. These solutions also eliminate any advantage which other thermal energy storage methods might offer. Such systems require the water that is frozen and the coil inside it to be located near the Freon compressor because of pressure losses in the Freon tubing between the compressor and the coil, compressor lubricating oil loss and entrapment in long runs of Freon tubing between the coil and compressor. The additional cost and inconvenience of the copper tubing connecting the coil and the compressor must be taken into consideration when the two are located apart at a relatively great distance. All such systems require one tank for each existing condensing unit and the location of the tank to be relatively close to the condensing unit.
In a typical installation, there are many buildings that are air conditioned by several conventional Freon air conditioners (usually one for each zone inside the building). As a result, a need has arisen for a method for several condensing units to be converted for thermal storage, which method also allows the condensing units to share the same storage tank. Because it has become common practice to mount conventional condensing units on the roof of the structure, a need has arisen for the common energy storage tank to be mounted on the ground and not on the roof due to the prohibitive weight of the storage tank.
Because there are several methods of storing thermal energy in a tank, there is a need for a device that enables a conventional Freon condensing unit to store and then retrieve thermal energy in the tank using any of the above cited methods of thermal energy storage, depending upon the particular situation at hand.
SUMMARY OF THE INVENTION
It is therefore one object of this invention to provide a thermal energy transfer unit which can be retrofitted to an existing Freon air conditioning system without the requirement that the storage tank be located in close proximity to the condensing unit.
It is another objective of this invention to provide a thermal energy transfer unit which can be retrofitted to several condensing units while sharing a single remote thermal energy storage tank, also allowing the storage tank to use any of the previously described methods of storing thermal energy.
It is another objective of this invention to provide a thermal energy transfer unit that transfers thermal energy from the existing condensing unit to the shared remote thermal energy storage tank during off-peak hours, while allowing recovery of this energy from the common tank during peak hours.
These objects are accomplished by means of the present thermal energy transfer unit (TETU). The TETU provides a method of applying thermal energy conversion and storage to an existing conventional Freon air-conditioner in such a manner that:
1. multiple systems can share a common energy storage tank; 2. the thermal energy storage can be by any one of several known methods; and 3. the thermal energy storage tank can be located remotely from the condensing unit(s).
The TETU uses a non-freezing liquid that never freezes in operation and transfers heat to and from the common storage tank. The liquid is circulated to and from the storage tank and the TETU by means of a pump that is located either at the tank or in the TETU. The TETU can include one or several heat exchangers which transfer heat from the non-freezing liquid to the Freon being circulated by the condensing unit when storing energy in the tank. The TETU uses this same heat exchanger, or others, to transfer the heat in the Freon to the non-freezing liquid (and thus to the tank) when air conditioning is performed without the condensing unit running. This heat transfer, without the use of the condensing unit, is accomplished by condensing the Freon to its liquid state and then pumping the liquid Freon into the building to absorb heat where it vaporizes. After the Freon absorbs heat and vaporizes inside the structure it returns to the heat exchanger(s) where it transfers its heat to the non-freezing liquid and condenses to its liquid state. The TETU also includes a pump means for pumping the liquid Freon when air conditioning is required without the condensing unit. The TETU allows normal air conditioning to be performed by the operation of the condensing unit as if the TETU were not present. In this case, heat is neither being added nor extracted to the non-freezing liquid and the non-freezing liquid pump is not running. The TETU is provided with appropriate valving and controls to accomplish these three functions. By using the TETU with each condensing unit, a common non-freezing liquid can be used to transfer heat to and from a common heat storage tank. By such means heat can be transferred at one air conditioner while another air conditioner is inactive. When using multiple TETU's, all can be transferring heat at the same time or any or all can be inactive.
Additional objects, features and advantages will be apparent in the written description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified schematic representation of a conventional Freon air conditioning system.
FIG. 2 is a similar schematic representation showing how multiple conventional Freon air conditioning systems are used in a single structure.
FIG. 3 is a schematic representation, similar to FIG. 1 , of one TETU working in conjunction with the conventional Freon air conditioning system and a remote thermal energy storage tank.
FIG. 4 is a schematic diagram of several TETU's working in conjunction with the multiple conventional Freon air conditioning systems described by FIG. 2 and a single common remote thermal storage tank.
FIGS. 5A–5D are simplified illustrations of several thermal storage systems currently being used in the industry.
FIG. 6 is a diagrammatic representation of the TETU operation of FIG. 3 with a pump located by the storage tank and flow controlled by a flow control valve.
FIG. 7 is a diagrammatic representation of the TETU operation of FIG. 4 with one liquid pump located at the tank and a flow control valve within each TETU to control the flow rate.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a conventional Freon air conditioning system on a building ( 1 ) to be cooled. In the discussion which follows, the term “Freon air conditioning” is intended to describe any conventional mechanical compression refrigeration or air conditioning system using a compressible refrigerant and an expansion device in a closed circuit to achieve a cooling effect. It will be understood that other refrigerants besides “Freon” will be known to those skilled in the relevant industries. The building has an evaporator coil ( 9 ), an expansion device ( 7 ), and a motorized air mover ( 10 ) located inside the building. The air inside the building ( 13 ) is moved past the evaporator coil when the motorized air mover ( 10 ) is running. Outside the structure ( 1 ) a conventional condensing unit ( 2 ) is shown. The condensing unit consists of a compressor ( 15 ), a condensing coil ( 4 ), and a motorized air moving unit ( 5 ). Outside air ( 14 ) is moved past the condensing coil ( 4 ) when the motorized air handler ( 5 ) is on and running.
The purpose of the air conditioner is to transfer heat from the inside air ( 13 ) to the outside air ( 14 ). The compressor ( 15 ) is the prime mover and comes on when the inside air temperature rises. The compressor ( 15 ) pulls the Freon from the evaporator coil ( 9 ) through line ( 11 ) where it is in a low pressure and vapor state. The compressor ( 15 ) compresses the vapor to a high pressure where it leaves the compressor at a high pressure and an elevated temperature in the vapor state. The compressed Freon then flows to the condensing coil ( 4 ) through tube ( 3 ). As outside air ( 14 ) moves across the condensing coil ( 4 ), the elevated temperature of the Freon vapor in the condensing coil ( 4 ) causes heat to transfer to the outside air ( 14 ). In this manner all of the heat absorbed from the inside air ( 13 ) and all the additional heat added to the Freon in the form of work during the compression is rejected to the outside air ( 14 ). As this heat is rejected to the outside air ( 14 ), the Freon inside the condensing coil ( 4 ) condenses to its liquid state at this elevated pressure. The Freon leaves the condensing coil ( 4 ) as a high pressure liquid through tube ( 6 ) traveling inside the structure to be cooled ( 1 ) to the expansion device ( 7 ). The expansion device ( 7 ) holds back pressure on the liquid.
There are several different types of expansion devices that can be used, all of which cause the pressure entering the device to be much higher than the discharge. The Freon leaves the expansion device at a low pressure through tube ( 8 ) and travels to the evaporator coil ( 9 ). Inside the evaporator coil ( 9 ), the Freon starts to vaporize because of the low pressure and heat added. As it vaporizes, the temperature of the Freon decreases until it is lower than the inside air ( 13 ) moving past the coil ( 9 ). Because of this low temperature, heat is transferred from the inside air ( 13 ) to the Freon as it vaporizes. The evaporator coil ( 9 ) and the motorized air mover ( 10 ) are sized such that all the Freon is vaporized in the evaporator coil ( 9 ). The Freon leaves the evaporator coil ( 9 ) through tube ( 11 ) returning to the compressor ( 15 ) where it again repeats the cycle. Typically the temperature of the inside air ( 13 ) is monitored. When the inside air temperature reaches a desired set point, the compressor ( 15 ) and motorized air movers ( 5 ) and ( 10 ) are turned off. When the inside air temperature rises they are turned on.
FIG. 2 is a schematic diagram showing an application with two zones ( 18 , 19 ) that are air conditioned by the method shown in FIG. 1 . Although one large air conditioner would be less expensive to provide than the two shown, using two smaller air conditioners has several advantages:
(1) one zone can be maintained at a temperature different from the other zone; (2) one zone does not need to be air conditioned if it is not occupied; and (3) the temperature of both zones is more easily maintained, eliminating the possibility of slow moving air warming while fast moving air cools.
As a result, it has become common practice to have several air conditioners cooling the same structure. In FIG. 2 , the process of removing heat from one zone ( 17 ) can be stopped by turning off the air conditioner ( 20 ) controlling that zone ( 17 ) while the other zone ( 18 ) continues to have heat removed because the air conditioner for that zone ( 21 ) continues to run. In this manner a structure can be divided into several zones with only the occupied zones being required to use electricity for air conditioning. It is common practice in the industry to see schools, office buildings, etc. with as many as fifty or more different zones and air conditioners being employed.
FIG. 3 is a simplified schematic illustration of the thermal energy transfer unit (TETU) ( 25 ) of the invention used in conjunction with the air conditioner described in FIG. 1 and a thermal storage tank ( 36 ). The thermal energy transfer unit (TETU) ( 25 ) consists of a means to transfer heat to or from a non-freezable liquid ( 38 ) a heat exchanger ( 31 ), an expansion device ( 28 ), a means of pumping liquid Freon ( 30 ), a means of pumping the non-freezable liquid ( 38 ) ( 32 ), and valves to control the Freon flow ( 27 ) ( 26 ) ( 29 ).
The primary purpose of the TETU ( 25 ) is to provide a method to:
1. transfer heat from a thermal storage media ( 37 ) in the thermal storage tank ( 36 ) to the condensing unit ( 2 ) where it is rejected to outside air ( 14 ); 2. transfer heat from the inside air ( 13 ) of the structure 1 to the thermal storage media ( 37 ) in the thermal storage tank ( 36 ) without the condensing unit ( 2 ) operating; and to 3. allow the condensing unit ( 2 ) to transfer heat from the inside air ( 13 ) of the structure ( 1 ) to outside air ( 14 ) in the same way which has been described in FIG. 1 before the TETU and storage tank ( 36 ) were added to the system.
Each of the above objectives of the invention will now be described in greater detail beginning with the transferring of heat from the storage media ( 37 ) to outside air ( 14 ).
The compressor ( 15 ) pulls in low pressure vaporized Freon from the common line ( 24 ). There the Freon is compressed to a high pressure where it leaves the compressor at a high temperature and in the vapor state through tube ( 3 ) and enters the condensing coil ( 4 ). The high pressure Freon enters the condensing coil ( 4 ) in its vapor state at a high temperature. Because of its high temperature, the Freon transfers the heat it gained from the heat exchanger ( 31 ) and the heat it gained from the compressor ( 15 ) to the flow of outside air ( 14 ) at a lower temperature across the condensing coil. As the Freon loses heat it condenses to its liquid state until it leaves the condensing coil in its liquid state at high pressure. The high pressure liquid Freon leaves the condensing coil through tube ( 23 ) past closed valve ( 26 ) and through open valve ( 27 ) to the expansion device ( 28 ). The expansion device ( 28 ) holds back pressure on the Freon and maintains the high pressure on its inlet side. The Freon leaves the expansion device ( 28 ) at low pressure through tube ( 39 ). It cannot enter the pump ( 30 ) because valve ( 29 ) is closed. Rather, the Freon enters the heat exchanger ( 31 ) at a low pressure and starts to vaporize at a low temperature. Because of the low temperature, it absorbs heat from the heat exchanger ( 31 ) until it is completely vaporized at low pressure.
The low pressure vaporized Freon leaves the heat exchanger and returns to the compressor suction through common tube ( 24 ) where it compresses again and repeats the cycle. While the condensing unit ( 2 ) is running the pump ( 32 ) is running. The pump ( 32 ) is pumping a non-freezing liquid ( 38 ) into the heat exchanger ( 31 ) where heat is removed from the non-freezing liquid ( 38 ). The non-freezing liquid leaves the heat exchanger ( 31 ) and enters the thermal energy storage tank ( 36 ) through tube ( 34 ) at a lower temperature than it left the tank ( 36 ) because of the heat lost in the heat exchanger ( 31 ). Once in the tank ( 36 ) the non-freezing liquid ( 38 ) absorbs heat from the thermal storage media ( 37 ). The non-freezing liquid ( 38 ) leaves the tank at a higher temperature than it entered the tank because of the heat it gained from the storage media ( 37 ). The non-freezing liquid ( 38 ) leaves the tank through tube ( 33 ) and returns to the pump ( 32 ) suction where it repeats the cycle. By this means heat is transferred from the media ( 37 ) to the heat exchanger ( 31 ) and then to the Freon where it is rejected to the outside air ( 14 ) while the condensing unit ( 2 ) is running.
The transfer of heat from the inside air ( 13 ) to the thermal storage media ( 37 ) is accomplished by the TETU ( 25 ) without the condensing unit ( 2 ) operating or consuming any electricity. The pump ( 32 ) moves the non-freezing liquid ( 30 ) in a cold state through the heat exchange ( 31 ). Because the non-freezing liquid ( 38 ) is colder than the Freon in the heat exchanger ( 31 ) the non-freezing liquid absorbs heat from the Freon. The non-freezing liquid leaves the heat exchanger ( 31 ) at a higher temperature than it entered the heat exchanger ( 31 ) because of the heat it gained from the Freon. The non-freezing liquid ( 38 ) leaves the heat exchanger ( 31 ) through tube ( 34 ) and enters the tank ( 36 ). Inside the tank ( 36 ) the non-freezing liquid ( 38 ) transfers the heat it gained in the heat exchanger ( 31 ) to the storage media ( 37 ) because it is at a higher temperature than the media ( 37 ). The non-freezing liquid ( 38 ) leaves the tank ( 36 ) at a lower temperature than it entered the tank ( 36 ) because of the heat rejected to the storage media ( 37 ). The non-freezing liquid leaves the tank through tube ( 33 ) and returns to the pump ( 32 ) where the cycle is repeated. While pump ( 32 ) is running the heat exchanger ( 31 ) is transferring heat from the low pressure vaporized Freon in the heat exchanger. This heat transfers because the temperature of the non-freezing liquid in the heat exchanger is lower than the low pressure vaporized Freon.
As heat is lost from the low pressure Freon in the heat exchanger ( 31 ) it condenses to its liquid state. The low pressure liquid Freon leaves the heat exchanger ( 31 ) through common tube ( 39 ). It can't go through the expansion devise ( 28 ) because valve ( 27 ) is closed. It enters the pump ( 30 ). The pump moves the Freon liquid through open valve ( 29 ), past closed valve ( 26 ) into tube ( 35 ). The liquid Freon enters the expansion device ( 7 ) through tube ( 35 ). The expansion device holds back pressure on the liquid entering the device. The pump must develop enough pressure to overcome the resistance offered by the expansion device ( 7 ). It is noted that the pump would be required to put out less pressure if there were a bypass around this expansion device ( 7 ), another expansion device in parallel to device ( 7 ), or a means to disable the expansion device ( 7 ) such that it held less back pressure in this mode. The Freon leaves the expansion device ( 7 ) at low pressure through tube ( 8 ) and enters the evaporator coil ( 9 ) at a low pressure. As the low pressure Freon enters the evaporator coil ( 9 ), it starts to vaporize at a temperature lower than the inside air ( 13 ) moving past the coil ( 9 ) with the motorized air mover ( 10 ) operating. Because the Freon is at a lower temperature than the air ( 13 ), heat is transferred from the air to the Freon until all the Freon is vaporized in the coil ( 9 ). The Freon leaves the evaporator coil ( 9 ) in its vapor state and returns to the heat exchanger through tube ( 11 ) where the heat absorbed from the inside air ( 13 ) is transferred to the non-freezing liquid ( 38 ) and thus to the storage media ( 37 ). When the temperature of the inside air ( 13 ) drops to the desired value, the pumps ( 30 ) and ( 32 ) stop. When the temperature rises above the desired set point, the pumps again start to operate.
Heat is transferred from the inside air ( 13 ) inside the structure ( 1 ) to the outside air ( 14 ) the same way as has been previously described with respect to FIG. 1 as if the TETU and tank ( 36 ) were not present. When valves ( 28 ) and ( 29 ) are closed Freon travels through open valve ( 26 ) when pumps ( 30 ) and ( 32 ) are off. The Freon cannot enter the heat exchanger because of the closed valves. It is understood that some Freon may accumulate in the heat exchanger during this mode, thereby reducing the Freon mass in circulation to the compressor. This shortage can be easily adjusted for with the use of an accumulator in the system. Such accumulators are commonly used in the air conditioning industry for such variances in mass flow rate and can be viewed in the “American Society of Heating, Refrigeration, and Air Conditioning Engineers Handbook 1998–2001.”
FIG. 4 is an illustration of TETU's ( 25 ) and ( 39 ) installed on the multiple condensing units illustrated in FIG. 2 . It can be easily seen that one remote thermal energy storage tank ( 36 ) is shared by the multiple units. Each zone can be cooled separately in the same fashion as illustrated in FIG. 2 . Each zone can be cooled separately with the operation of each separate TETU. Even though all units share the same thermal energy storage tank, all units can run at the same time or run alone without the others running. In the same manner, all units can transfer heat from the tank's thermal storage media ( 37 ) to the outside air at the same time or one unit can transfer with the others units being off. One zone can be air conditioned by the conventional method described in FIG. 1 while others are transferring heat from the media ( 37 ) to outside air ( 14 ).
FIGS. 5A–5D illustrate several examples of conventional methods of storing thermal energy. All include an insulated tank ( 36 ), a liquid ( 38 ) that is circulated through the tank to add or extract heat, a substance to store and withdraw the heat ( 37 ), an inlet line ( 34 ) for the liquid ( 38 ) and an outlet line ( 33 ) for the liquid.
In FIG. 5A the circulation liquid ( 38 ) is the same as the storage substance ( 37 ). Thermal storage is accomplished by simply lowering the temperature of the liquid without a phase change (conversion from liquid to solid). The advantage of this method is simplicity. The disadvantage is the large amount of liquid required for storage (only one BTU per degree Fahrenheit temperature change for one pound of water compared to 144 BTU per pound of water when changed to ice).
FIG. 5B is an example of the “ice on pipe” thermal energy storage method. The tank ( 36 ) has a coil ( 39 ) that runs throughout the storage media ( 37 ). The circulation liquid ( 38 ) is circulated through the coil ( 39 ) with heat being added or extracted outside the tank. When heat is being extracted from this liquid ( 38 ) heat is transferred from the storage substance ( 37 ) until it changes phase to its solid state. This is a large amount of heat transfer (144 BTU per pound when water is used). When heat is being absorbed into the circulating liquid ( 38 ) outside the tank, the temperature of this liquid rises, causing heat to be transferred through the coil ( 39 ) into the storage media ( 37 ). The advantage of this method is the large amount of heat stored per volume of tank space (8,900 BTU per cubic ft when water is used). The disadvantage is the cost and complexity of the coil ( 39 ) and heat exchange problems around the coil ( 39 ).
FIG. 5C is an example of “ice ball storage”. An example of ice ball storage can be understood by reviewing U.S. Pat. No. 4,768,579, issued to Patry. The tank ( 36 ) contains a plurality of plastic balls ( 40 ), each filled with a storage substance ( 37 ) which changes state. The balls are submerged and surrounded by the circulated liquid ( 38 ). If heat is extracted from the circulating liquid ( 38 ) outside the tank ( 36 ), the circulating liquid ( 38 ) becomes cold and extracts heat inside the tank from the ice balls ( 40 ) until the media ( 37 ) inside the balls ( 40 ) freezes. When heat is being added to the circulating liquid ( 37 ) outside the tank, the temperature of the liquid rises. This causes heat to be transferred (added) to the ice balls ( 40 ) until they thaw (return to their liquid state). The advantage of this method is the elimination of the coil in FIGS. 5-2 with nearly the same results. The disadvantage is the cost of the balls ( 40 ).
FIG. 5D is a simplified representation of an ice slurry method of thermal storage. This method suspends the thermal storage media ( 37 ) chemically in the circulation liquid ( 38 ). The storage media ( 37 ) undergoes a change of state to its solid state and remains in the tank as solid particles when heat is extracted from the circulating liquid ( 38 ) outside the tank ( 36 ). When heat is added to the circulation liquid ( 38 ) outside the tank, the circulation liquid ( 38 ) temperature rises and causes heat to be transferred inside the tank to the frozen particles of storage media ( 37 ) until they thaw back to their liquid state. When they return to their liquid state, they are dissolved by the circulation liquid ( 38 ) and circulate with the circulation liquid ( 38 ). An example of this type of thermal storage is ice slurry beverages sold by convenience stores where the storage media ( 37 ) is water and the circulating liquid ( 38 ) is syrup. The advantage of this method is the elimination of the need for a coil or ice balls inside the tank while still achieving change of state storage. The disadvantage of this method is a problem of coating the heat exchanger outside the tank with frozen storage media ( 37 ) when extracting heat from the circulating liquid ( 38 ).
There are several variations of each of the discussed methods and all are currently being used for thermal storage.
FIG. 6 is a description of the operation of the TETU working as FIG. 3 describes with the exception of the non-freezing liquid pump ( 32 ) being moved to the storage tank discharge and replaced with a modulating control valve ( 41 ). The operation of the TETU is identical to that described by FIG. 3 except the modulating control valve ( 41 ) opens or closes depending on the load of heat transfer required by the heat exchanger ( 31 ). This loading can be monitored by conventional methods of monitoring the temperature and/or pressure of the lines ( 34 ), ( 24 ), and/or ( 35 ). When the load increases valve ( 41 ) opens and when it falls, valve ( 41 ) would tend to close. This action would cause more or less flow rate of the circulating non-freezing liquid. As this valve ( 41 ) opens or closes, the pressure changes in line ( 33 ) feeding the valve. This pressure change is sensed by the pressure transducer ( 42 ) which in turn changes the pumping rate of the pump ( 32 ).
FIG. 7 is a description of the operation of multiple units running as described by FIG. 4 with the pumps being substituted as described by FIG. 6 . It can easily be seen that pump ( 32 ) whose speed is controlled by pressure transducer ( 42 ) varies the flow rate in lines ( 33 ) and ( 34 ) as the total demand of all heat exchangers ( 31 ) varies.
While the invention has been shown in several of its forms, it is not thus limited but is susceptible to various changes and modifications without departing from the spirit thereof.
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A thermal energy transfer unit is provided for conventional Freon air conditioning. One or several thermal energy transfer units are operatively interconnected to one or several conventional air condition systems and share a common energy storage tank. Each thermal energy transfer unit converts energy from the compressor and condensing coil of the conventional air conditioner and stores it in the common energy storage tank when electricity is in low demand. Each thermal energy transfer unit retrieves stored energy from the common storage tank and provides air conditioning without the use of the compressor when electricity is in high demand. Each thermal energy transfer unit can be disabled to allow the air conditioning unit to perform as if they and the energy storage tank were not connected. One or all of the units can be disabled without affecting the performance or purpose of the others.
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[0001] This application is a continuation in part of U.S. application Ser. No. 10/859,304, filed Jun. 2, 2004.
FIELD OF THE INVENTION
[0002] The invention relates to anti-skinning agents containing mixtures of compounds (combinations of additives), coating compositions containing them and articles coated with them. The compounds are selected from the groups of (a) organic and inorganic oxygen scavengers with (b) amines including alkyl amines and/or alkyl alkanolamines. The invention further relates to compositions containing these anti-skinning agents, like coating compositions such as oxidatively drying alkyd resins.
BACKGROUND OF THE INVENTION
[0003] Colorless and pigmented oxidatively drying paints and coatings based on oxidatively drying oils, alkyd resins, epoxy esters and other oxidatively drying refined oils are known. These oils and binders crosslink oxidatively under the influence of oxygen (preferably atmospheric oxygen) by means of the addition of driers, such as metal carboxylates of transition metals. If this crosslinking takes place before the product is actually used, they can form a solid barrier film, a skin, on the surface when stored in open or closed containers. This is highly undesirable and should therefore be avoided since it makes the paint more difficult to work with, and commonly interferes with the uniform distribution of the driers. The accumulation of the driers in the paint skin that forms can lead to considerable delays in the drying of the paint when it is applied.
[0004] Skinning of the paint film after application is also disadvantageous. Excessively rapid drying of the surface of the paint prevents the lower film layers from drying evenly because they are shielded from oxygen, which is prevented from sufficiently penetrating into and dispersing within the paint film. This can lead among other things to flow problems in the paint film, adhesion problems, or insufficiently hard films.
[0005] It is known to add organic substances to a paint that inhibit the reaction of the drier metal with (atmospheric) oxygen by binding the oxygen or by complexing of the drier metal.
[0006] U.S. Pat. No. 4,618,371 describes the use of aliphatic α-hydroxy ketones as anti-skinning agents. DE-A 1 519 103. discloses N,N-dialkylated hydroxylamines for this purpose. Because of their low volatility, however, hydroxylamines alone can lead to severe delays in drying and often also to reduced film hardness values, so that their possible applications are limited. They have not been able to gain commercial acceptance as anti-skinning agents. U.S. patent application publication No. 2003/0025105 describes the use of organic hydroxylamines such as diethylhydroxylamine and β-dicarbonyl compounds such as diethylformamide as anti-skinning agents.
[0007] A central issue in alkyd resin technology is to quickly cure the resin which occurs via oxidative crosslinking, while maintaining adequate anti-skinning properties. Anitskinning requires slowing the curing reaction at the air-resin interface. Oximes, which act as oxygen scavengers, or suitable phenolic compounds are most often used today as anti-skinning agents in industry. However, the phenolic anti-skinning agents display a significant delay in surface drying such that alone they are only suitable for certain coating compositions. Oximes such as e.g. methyl ethyl ketoxime (MEKO) or butyraldoxime, on the other hand, display only slight delays in surface drying due to their volatility. However, the high volatility of oximes results in rapid loss of this anti-skin agent from the alkyd and thus does not adequately control skinning. The most significant disadvantage of the oximes, which are widely used today, lies in their toxicity. As a consequence of this, users have to observe elaborate personal protection precautions when working with paints containing oximes as anti-skinning agents.
[0008] It was discovered that the use of the combination of an antiskinning agent and a co-promoter as described below provides for inhibition of skinning with minimal impact on drying properties. In particular, the above-mentioned disadvantages of the specified hydroxylamines as anti-skinning agents could also be avoided by combining such substances with the additional compounds described below, and hence products that better satisfy requirements as anti-skinning agents are obtained.
[0009] Incorporating the combinations according to the present invention into an air-drying alkyd resin provides an alkyd resin system which is resistant to undesirable skinning and exhibits improved drying of the resin films after application.
DETAILED DESCRIPTION OF THE INVENTION
[0010] The present invention relates to an anti-skinning agent containing
[0011] a) an organic or inorganic oxygen scavenger,with either or both of
[0012] b) an organic alkyl amine compound of formula II
where R 3 , R 4 and R 5 may be mutually independently hydrogen but all three can not be hydrogen, a linear or branched, saturated or unsaturated C 1 -C 20 aliphatic molecule or radical, which can optionally be mono- or polysubstituted, or a C 6 -C 12 aryl molecule or radical, a C 7 -C 14 araliphatic molecule or radical or a C 5 -C 7 cycloaliphatic molecule or radical, and
[0013] c) an organic alkyl alkanolamine compound of formula (III)
where R 6 and R 8 may be mutually independently hydrogen but both can not be hydrogen, a linear or branched, saturated or unsaturated C 1 -C 20 aliphatic molecule or radical, which can optionally be mono- or polysubstituted, a C 6 -C 12 aryl radical, a C 7 -C 14 araliphatic molecule or radical or a C 5 -C 7 cycloaliphatic molecule or radical and R 7 may be a linear or branched, saturated or unsaturated C 1 -C 20 aliphatic molecule or radical, which can optionally be mono- or polysubstituted, a C 6 -C 12 aryl molecule or radical, a C 7 -C 14 araliphatic molecule or radical or a C 5 -C 7 cycloaliphatic molecule or radical.
[0014] An organic or inorganic oxygen scavenger is a material which exhibits the ability to complex with free oxygen and slow its oxidative reactions. Representative examples of organic oxygen scavengers include but are not limited to: hydroquinone, substituted hydroquinones, semi-hydroquinone, catechol, substituted catechols, erythorbic acid, hydroxylamine compounds, carbohydrazides and methyl ethyl ketoxime. Representative examples of inorganic oxygen scavengers include but are not limited to sulfites.
[0015] Hydroxylamine oxygen scavengers in accordance with the present invention are of the general formula:
where R 1 and R 2 mutually independently hydrogen, a linear or branched, saturated or unsaturated C 1 -C 20 aliphatic molecule or radical, which can optionally be mono- or polysubstituted, or a C 6 -C 12 aryl molecule or radical, a C 7 -C 14 araliphatic molecule or radical or a C 5 -C 7 cycloaliphatic.
[0016] Representative hydroxylamines include but are not limited to: hydroxylamine, methylhydroxylamine, dimethylhydroxylamine, methyl-ethylhydroxylamine, ethylhydroxylamine, diethylhydroxylamine, dibutylhydroxylamine, dibenzylhydroxylamine, mono-isopropylhydroxylarnine and mixtures thereof.
[0017] Hydroquinone oxygen scavengers in accordance with the present invention may be unsubstituted or substituted. The substituted hydroquinone oxygen scavengers can be substituted in the ortho or meta positions or both with moieties including but not limited to C-1 to C6 alkyl or aryl moieties. Representative examples of substituted hydroquinones include but are not limited to methyl hydroquinone.
[0018] Representative organic alkyl amines include but are not limited to: monoethyl amine, diethyl amine, triethyl amine, monoisopropyl amine, diisopropyl amine, monobutyl amine, dibutylamine, tributyl amine, monoamyl amine, dimethyl ethyl amine, dimethyl isopropyl amine, ethyl diisopropyl amine, sec-butyl amine, tetramethylpropylenediamine, diethylaminopropylamine, 3-methoxypropylamine, dimethylaminopropylaminopropylamine and 3-isopropoxypropylamine and mixtures thereof.
[0019] Representative organic alkyl alkanolamines include but are not limited to: methylaminoethanol, dimethylaminoethanol, methydiethanolamine, ethylaminoethanol, diethylaminoethanol, dimethylamino-2-propanol, isopropylaminoethanol, disiopropylaminoethanol, butylaminoethanol, dibutylaminoethanol, butyldiethanolamine, tert-butylaminoethanol and mixtures thereof.
[0020] The invention also relates to compositions of matter containing these anti-skinning agents.
[0021] For the purposes of the invention mixtures of one or more organic or inorganic oxygen scavengers and either or both an organic alkyl amine and/or an organic alkyl alkanolamine compound are used alone or as solutions or dispersions or emulsions in water and/or organic solvents. Suitable organic solvents include all conventional solvents, such as aromatics, white spirits, ketones, alcohols, ethers and fatty acid esters. The present invention provides for a novel means of balancing the need for a rapid dry through of an alkyd resin coating while maintaining an acceptable oxidative control at the air-resin interface to control skinning.
[0022] For the use according to the present invention the one or more organic or inorganic oxygen scavengers (A) and either or both an organic alkyl amine (B) and/or an organic alkyl alkanolamine (C) can be used in a broad range of mixtures with one another. They are preferably used in the ratio (A):(B) and/or (C)=from 0.01:75 to 75:0.01, preferably from 0.05:30 to 30:0.05 and most preferably from 0.1:10 to 10:0.1 parts. In a mixture consisting of all three components, each of the components can mutually independently preferably be used in the ratio 0.1 to 10 to each of the other components used. They can be used in pure form or in aqueous solution or aqueous dispersion or emulsion or in the form of solutions in organic solvents. Aqueous in this context is intended to mean that water is either the sole solvent or is added in a quantity of over 50 wt. % relative to the solvent blend together with conventional organic solvents (e.g. alcohols).
[0023] The amount of anti-skinning agent combination used in a coating system primarily depends on the content of binder and drier used in the particular coating composition. As a general rule between 0.001 and 2.0 wt. % of mixtures of compounds according to the present invention should be added. Preferred amounts to be used are 0.01 to 0.5 wt. %, relative in each case to the overall composition of the coating composition. The amounts can also depend on the type of binder and the pigments used in the coating composition. Thus, in special systems the relative amount of additive to be used can also be greater than 2.0 wt. % (relative to the overall composition).
[0024] It is an advantage of the anti-skinning agent combination of the present invention that it reliably prevents skinning in a wide range of binders and when used with various driers but that it does not unfavorably influence other drying properties of the resin.
[0025] The invention is further illustrated but is not intended to be limited by the following examples in which all parts and percentages are by weight unless otherwise specified.
EXAMPLES
[0026] In examples 1 through 6 a common short oil resin, Beckosol 12054 (available from Reichhold Chemicals, Inc.), containing 50% solids was used. In examples 7 through 12, tung oil was used as the curing medium, with cobalt II added as a drying agent. When cobalt II is added to tung oil, it quickly causes curing and the formation of a hard surface film.
Example 1
[0027] This example shows the performance of a hydroxylamine, diethylhydroxylamine (DEHA)-amine formulations containing no additional volatile organic compounds such as diethyl formamide (DEF) in a short oil alkyd resin (Beckosol 12054). MEKO (methyl ethyl ketoxime) was compared to combinations of DEHA and alkyl amines or alklyl alkanolamines. Cobalt octoate was added to the resin so the final cobalt ion concentration was 0.2%. To the resin-cobalt mixture was added MEKO (available as a 25% active solution), DEHA with diethyl formamide (DEF), as a 14% active solution or DEHA with either alkyl amines or alkyl alkanolamines. The samples were prepared on an eqi-molar basis using 750 ppm of DEHA (e.g., 750 mg/l; 0.0084 mol DEHA/l). Ten-gram samples were placed in bottles and a small hole was drilled into the cap so air could enter into the bottles. Air was swept over the top of the bottles using a flow rate of about 100 feet per minute. The onset of skinning was monitored daily with the following results:
TABLE 1 Diethylhydroxylamine Diethylhydroxylamine Diethylhydroxylamine MEKO MEKO (0.065 mmol) + Diethyl Diethylhydroxylamine (0.069 mmol) + (0.066 mmol) + Dibutyl (0.055 mmol (0.114 mmol formamide (0.068 mmol) + Diisoproplyaminoethanol Ethylaminoethanol amine active) active) (0.016 mmol) (0.018 mmol) (0.018 mmol) (0.016 mmol) 13 Days 20 Days 62 Days >70 Days >70 Days >70 Days
[0028] The MEKO samples showed poor resistance to skinning even at 0.114 mmol concentration. The sample containing diethylhydroxylamine with the co-solvent diethyl formamide showed better anti-skinning performance than MEKO. The samples containing diethylhydroxylamine with either an alkyl amine or alkyl alkanolamine showed the overall best anti-skinning performance. The surfaces of the last three samples were only tacky and not completely skinned even after 70 days of exposure to air.
[0029] Similar skinning results were found with other combination of diethylhydroxylamine and other alkyl amines such as diisopropyl amine (DiPA), tributyl amine (TBA) and triethyl amine (TEA), all samples were tacky and not completely skinned after 70 days. Similarly, combinations of diethylhydroxylamine with other alkyl alkanolamines such as dibutylaminoethanol (DBAE) also delayed skinning to greater than 70 days. In all cases, the total concentration of DEHA with either the alkyl amine or the alkyl alkanolamines was about 0.081 mmol in the ten-gram sample or about 8 mmol/kg of resin.
Example 2
[0030] This example shows the dry-through performance of the short-oil resin used in Example 1 with eqimolar amounts of prior art antiskinning agents, and those of the present invention based on 750 ppm DEHA (0.084 mmol DEHA/10 gram of resin). The cobalt concentration for this dry-through performance study was decreased to 0.1%. The combinations of resin with the cobalt drier and the antiskinning agents were placed onto a substrate and a drawdown bar was used to apply a three mil thick coating. The samples were placed in an exhaust hood with air flowing over the samples at about 100 feet per minute. The tack-free time was determined by the absence of a fingerprint on the resin.
[0031] The dry-through performance was monitored using a methyl ethyl ketone (MEK) double-rub. Cheesecloth was soaked in MEK for about ten seconds then applied to the resin using a downward force of one pound per square in (1 psi). One complete rub was counted as a forward and backward stroke. The number of double-rubs necessary to remove the resin is an indication of the dry-through: the higher the number of MEK double rubs (DR), the faster the dry-through. Table 2 summarizes the results.
TABLE 2 MEKO (0.337 mmol) Borcher 0241 (0.337 mmol × 25% = (0.588 mmol) DEHA (0.068 DEHA (0.068 0.084 mmol (0.588 mmol × 14% = DEHA Only mmol) + DBAE mmol) + EAE DEHA (0.068 mmol) + DiPAE active 0.082 mmol Drying Time (0.086 mmol) (0.017 mmol) (0.017 mmol) (0.017 mmol) MEKO) active material) 1 3 4 5 6 7 8 Tack Free Tack Free Tack Free Tack Free Tack Free Time < 3 mins Tack Free Time < Tack Free Time < 3 mins Time < 3 mins Time < 3 mins Time < 3 mins 3 mins Time < 3 mins 3 Hours MEK DRs < 3 MEK DRs < 3 MEK DRs < 3 MEK DRs < 3 MEK DRs < 3 MEK DRs < 3 27 Hours MEK DRs 2 MEK DRs 2 MEK DRs 2 MEK DRs 2 MEK DRs 10 MEK DRs 2 124 Hours MEK DRs 6 MEK DRs 6 MEK DRs 6 MEK DRs 6 MEK DRs 10 MEK DRs 7 264 Hours MEK DRs 20 MEK DRs 30 MEK DRs 30 MEK DRs 35 MEK DRs 30 MEK DRs 30 480 Hours MEK DRs 25 MEK DRs 25 MEK DRs 25 MEK DRs 30 MEK DRs 30 MEK DRs 30
[0032] As shown in Table 2, the resin containing the MEKO anti-skinning agent showed the fastest dry-through rate due to the high volatility of MEKO but yielded the poorest anti-skinning performance as seen in Example 1. The samples containing DEHA with an alkyl alkanolamine showed similar dry-through properties to the sample containing DEHA with DEF.
[0033] Example 2 shows that the combination of diethylhydroxylamine with an alkyl alkanolamine showed increased resistance to skinning, without compromising dry-through performance in comparison to the prior art MEKO and DEHA with DEF.
Example 3
[0034] This example shows the dry-through performance of the short-oil resin used in Example 1 with eqimolar amounts of antiskinning agents using alkyl amines, based on 750 ppm DEHA (0.084 mmol DEHA/10 gram of resin). The same procedure used in Example 2 was used in Example 3.
TABLE 3 MEKO (0.337 mmol) Diethylhydroxylamine (0.337 mmol × 25% = (0.065 mmol) + Diethyl DEHA (0.068 DEHA (0.068 DEHA (0.069 0.084 mmol formamide mmol) + DiPA DEHA (0.068 mmol) + DBA mmol) + TBA mmol) + TEA Drying Time active MEKO) (0.016 mmol) (0.017 mmol) (0.017 mmol) (0.017 mmol) (0.017 mmol) Tack Free Tack Free Tack Free Time < 3 mins Tack Free Tack Free Time < 3 mins Tack Free Tack Free Time < 3 mins Time < 3 mins Time < 3 mins Time < 3 mins Time < 3 mins 3 Hours MEK DRs < 3 MEK DRs < 3 MEK DRs < 3 MEK DRs < 3 MEK DRs < 3 MEK DRs < 3 27 Hours MEK DRs 10 MEK DRs 2 MEK DRs 2 MEK DRs 2 MEK DRs 2 MEK DRs 2 124 Hours MEK DRs 10 MEK DRs 7 MEK DRs 8 MEK DRs 10 MEK DRs 11 MEK DRs 10 264 Hours MEK DRs 30 MEK DRs 30 MEK DRs 25 MEK DRs 30 MEK DRs 25 MEK DRs 30 480 Hours MEK DRs 30 MEK DRs 30 MEK DRs 25 MEK DRs 30 MEK DRs 30 MEK DRs 30
[0035] The resin containing the MEKO anti-skinning agent showed the fastest dry-through rate due to the high volatility of MEKO but yielded the poorest anti-skinning performance as seen in Example 1. The samples containing DEHA with an alkyl amine showed better dry-through performance after 124 hours than the sample containing DEHA with DEF. The samples containing DEHA with an alkyl amine showed similar results after 264 and 480 hours to the Borcher 0241 (DEHA with DEF available from Borcher GmbH Ltd.) but enhanced anti-skinning performance as seen in Example 1.
[0036] Example 3 shows that the combination of diethylhydroxylamine with an alkyl amine showed increased resistance to skinning, without compromising dry-through performance in comparison to the prior art MEKO and DEHA with DEF.
Example 4
[0037] This example shows the performance of DEHA-alkyl alkanolamine formulations containing no additional volatile organic compounds such as DEF in a medium oil resin. A common medium oil resin, Beckosol 11081 (available form Reichhold Chemicals, Inc.) containing 50% solids was used to compare MEKO to combinations of DEHA and alkyl alkanolamines. Cobalt octoate was added to the resin so the final cobalt ion concentration was 0.2%. To the resin-cobalt mixture was added MEKO, or DEHA with an alkyl alkanolamine. Ten-gram samples were prepared on an eqimolar basis using 750 ppm (e.g., 750 mg/l; 0.0084 mol DEHA/l) of diethylhydroxylamine hydroxide (DEHA).
TABLE 4 Diethylhydroxylamine Diethylhydroxylamine Diethylhydroxylamine MEKO MEKO (0.065 mmol) + Diethyl (0.068 mmol) + (0.069 mmol) + (0.055 mmol (0.114 mmol formamide Diisoproplyaminoethanol Ethylaminoethanol active) active) (0.016 mmol) (0.018 mmol) (0.018 mmol) 2 Days 7 Days 32 Days 37 Days 37 Days
[0038] The MEKO samples showed poor resistance to skinning even at 0.114 mmol. The sample containing diethylhydroxylamine with diethyl formamide showed better skinning performance than the MEKO samples. The samples containing diethylhydroxylamine with alkyl alkanaolamines, DiPAE or EAE showed the best overall skinning performance. The skinning performance of the samples containing DEHA with an alkyl alkanolamine performed better than that containing DEHA with DEF yet no additional co-solvents were necessary in the DEHA-alkyl alkanolamine samples.
Example 5
[0039] This example shows the dry-through performance of the medium oil resin used in Example 4 with eqimolar amounts of antiskinning agents, based on 750 ppm DEHA (˜0.085 mmol DEHA/10 gram of resin). The cobalt concentration for the dry-through performance study was decreased to 0.1%. The resin with the cobalt drier and the antiskinning agents were placed onto substrate and a drawdown bar was used to apply a three mil thick coating. The samples were placed in an exhaust hood with air flowing over the samples at about 100 feet per minute. The tack-free time was determined by the absence of a fingerprint on the resin.
TABLE 5 MEKO (0.4487 mmol) (0.4487 mmol × 25% = 0.112 mmol Diethylhydroxylamine Drying active (0.085 mmol) + Diethyl DEHA DEHA (0.068 mmol) + DiPAE DEHA (0.068 mmol) + TBA Time MEKO) formamide (0.026 mmol) (0.090 mmol) (0.017 mmol) (0.017 mmol) Tack- Tack Free Time > Tack Free Time > 2 Hours Tack Free Tack Free Time > 2 Hours Tack Free Time > 2 Hours Free 2 Hours Time > 2 Hours 3.5 MEK DRs 11 MEK DRs 8 MEK DRs 7 MEK DRs 8 MEK DRs 7 Hours 30 MEK DRs 14 MEK DRs 11 MEK DRs 8 MEK DRs 9 MEK DRs 9 Hours 146 MEK DRs 14 MEK DRs 12 MEK DRs 12 MEK DRs 12 MEK DRs 12 Hours
[0040] The resin containing the MEKO anti-skinning agent showed the fastest dry-through rate due to the high volatility of MEKO but yielded the poorest anti-skinning performance as seen in Example 1. After about 30 hours, the samples containing DEHA with either an alkyl amine (TBA) or an alkyl alkanolamine (DiPAE) showed similar dry-through performance to the DEHA sample containing the DEF but no additional VOC are present as with the use of DEF.
Example 6
[0041] This example shows the dry-through performance of the medium oil resin used in Example 4 with eqimolar amounts of antiskinning agents based on 750 ppm DEHA (˜0.085 mmol DEHA/10 gram of resin). However, the DEHA concentration was lowered to 0.0515 mmol and the amine concentration was increased to 0.0340 mmol. The cobalt concentration for the dry-through performance study was 0.1%. The resin with the cobalt drier and the antiskinning agents were placed onto a substrate and a drawdown bar was used to apply a three mil thick coating. The samples were placed in an exhaust hood with air flowing over the samples at about 100 feet per minute. The tack-free time was determined by the absence of a fingerprint on the resin.
TABLE 6 MEKO (0.4487 mmol) (0.4487 mmol × 25% = 0.112 mmol Diethylhydroxylamine Drying active (0.085 mmol) + Diethyl DEHA DEHA (0.0515 mmol) + DiPAE DEHA (0.0515 mmol) + TBA Time MEKO) formamide (0.026 mmol) (0.090 mmol) (0.0342 mmol) (0.0342 mmol) Tack- Tack Free Time > Tack Free Time > 2 Hours Tack Free Tack Free Time > 2 Hours Tack Free Time > 2 Hours Free 2 Hours Time > 2 Hours 3.5 MEK DRs 11 MEK DRs 8 MEK DRs 7 MEK DRs 8 MEK DRs 10 Hours 30 MEK DRs 14 MEK DRs 11 MEK DRs 8 MEK DRs 10 MEK DRs 11 Hours 146 MEK DRs 14 MEK DRs 12 MEK DRs 12 MEK DRs 14 MEK DRs 13 Hours
[0042] The resin containing the MEKO anti-skinning agent showed the fastest dry-through rate due to the high volatility of MEKO but yielded the poorest anti-skinning performance as seen in Example 1. After about 30 hours, the samples containing DEHA with either an alkyl amine (TBA) or an alkyl alkanolamine (DiPAE) showed similar dry-through performance to the DEHA sample containing the DEF but no additional VOC are present as with the use of DEF.
Examples 7
[0043] Additional testing of the antiskinning properties of antiskinning agents alone and with co-promoters was undertaken. The test solutions, A through L as described below were prepared. Tung oil was used as the curing medium. When cobaltous, Co(II), is added to tung oil it quickly causes curing, loss of cis unsaturation in the oil producing a hard film. Addition of an anti-skin agent can slow the curing of tung oil.
[0044] Tung oil in combination with cobalt (Co) dryer was used as a resin matrix in this example. The resin matrix was formed from a 150 gram sample of tung oil to which was added 0.1% by weight of Co(II) (Co 12 available from OMG America, Westlake, Ohio). The cobalt was adequately mixed into the tung oil.
[0045] Concentrated anti-skin agent and anti-skin agent/co-promoter solutions were prepared as follows:
[0046] Solution A: Methyl ethyl ketoxime: 25% active solution in mineral spirits: added 1.40 grams of this 25% active solution into 8.60 grams of mineral spirits.
[0047] Solution B: Hydroquinone (HQ): dissolved 1.402 grams HQ into 8.60 grams into mineral spirits.
[0048] Solution C: Methylhydroquinone (MeHQ): dissolved 1.401 grams MeHQ into 8.60 grams of mineral spirits.
[0049] Solution D: Methyl ethyl ketoxime (MEKO)/Diisopropylaminoethanol (DiPAE) -MEKO, as a 25% active solution in mineral spirits: added 1.093 grams of this 25% active MEKO solution along with 0.307 grams DiPAE into 8.60 grams of mineral spirits.
[0050] Solution E: Hydroquinone (HQ)/Diisopropylaminoethanol (DiPAE): dissolved 0.7484 grams HQ and 0.6516 grams of DiPAE into 8.60 grams into mineral spirits.
[0051] Solution F: Methylhydroquinone (MeHQ)/Diisopropylaminoethanol (DiPAE):
[0052] dissolved 0.7900 grams MeHQ and 0.610 grams DiPAE into 8.60 grams of mineral spirits.
[0053] Solution G: Methyl ethyl ketoxime: 25% active solution in mineral spirits: added 1.403 grams of this 25% active solution into 8.60 grams of water.
[0054] Solution H: Hydroquinone (HQ): dissolved 1.406 grams HQ into 8.60 grams into water.
[0055] Solution I: Methylhydroquinone (MeHQ): dissolved 1.402 grams MeHQ grams into 8.60 grams of water.
[0056] Solution J: Methyl ethyl ketoxime (MEKO)/Diisopropylaminoethanol (DiPAE): 25% active solution MEKO in mineral spirits: added 1.093 grams of this 25% active solution along with 0.307 grams DiPAE into 8.60 grams of water.
[0057] Solution K: Hydroquinone (HQ)/Diisopropylaminoethanol (DiPAE): dissolved 0.7484 grams HQ and 0.6516 grams of DiPAE into 8.60 grams into water.
[0058] Solution L: Methylhydroquinone (MeHQ)/Diisopropylaminoethanol (DiPAE): dissolved 0.7900 grams MeHQ and 0.610 grams DiPAE into 8.60 grams of water.
[0059] The above solutions were formulated into the following samples and the onset of skin formation evaluated.
[0060] Sample 1: No Antiskin Agent: A 10 gram sample was tung oil/Co drier placed in a glass bottle. The bottle was placed in an exhaust hood with air flowing over the top of the glass bottle at the rate of approximately 100 ft 3 /minute.
[0061] Sample 2: To a 10 gram sample of tung oil/Co drier was added 0.2096 grams of Solution A above (MEKO in mineral spirits). The solution was mixed in a glass bottle and placed in an exhaust hood with air flowing over the top of the glass bottle at the rate of approximately 100 ft 3 /minute.
[0062] Sample 3: To a 10 gram sample of tung oil/Co drier was added 0.0675 grams of Solution B above (HQ in mineral spirits). The solution was mixed in a glass bottle and placed in an exhaust hood with air flowing over the top of the glass bottle at the rate of approximately 100 ft 3 /minute.
[0063] Sample 4: To a 10 gram sample of tung oil/Co drier was added 0.0759 grams of Solution C above (MeHQ in mineral spirits). The solution was mixed in a glass bottle and placed in an exhaust hood with air flowing over the top of the glass bottle at the rate of approximately 100 ft 3 /minute.
[0064] Sample 5: To a 10 gram sample of tung oil/Co drier was added 0.1610 grams of Solution D above (MEKO/DiPAE in mineral spirits). The solution was mixed in a glass bottle and placed in an exhaust hood with air flowing over the top of the glass bottle at the rate of approximately 100 ft 3 /minute.
[0065] Sample 6: To a 10 gram sample of tung oil/Co drier was added 0.0759 grams of Solution E above (HQ/DiPAE in mineral spirits). The solution was mixed in a glass bottle and placed in an exhaust hood with air flowing over the top of the glass bottle at the rate of approximately 100 ft 3 /minute.
[0066] Sample 7: To a 10 gram sample of tung oil/Co drier was added 0.0812 grams of Solution F above (MeHQ/DiPAE in mineral spirits). The solution was mixed in a glass bottle and placed in an exhaust hood with air flowing over the top of the glass bottle at the rate of approximately 100 ft 3 /minute.
[0067] Sample 8: To a 10 gram sample of tung oil/Co drier was added 0.2091 grams of Solution G above (MEKO in water). The solution was mixed in a glass bottle and placed in an exhaust hood with air flowing over the top of the glass bottle at the rate of approximately 100 ft 3 /minute.
[0068] Sample 9: To a 10 gram sample of tung oil/Co drier was added 0.0671 grams of Solution H above (HQ in water). The solution was mixed in a glass bottle and placed in an exhaust hood with air flowing over the top of the glass bottle at the rate of approximately 100 ft 3 /minute.
[0069] Sample 10: To a 10 gram sample of tung oil/Co drier was added 0.0762 grams of Solution I above (MeHQ in water). The solution was mixed in a glass bottle and placed in an exhaust hood with air flowing over the top of the glass bottle at the rate of approximately 100 ft 3 /minute.
[0070] Sample 11: To a 10 gram sample of tung oil/Co drier was added 0.1599 grams of Solution J above (MEKO/DiPAE in water). The solution was mixed in a glass bottle and placed in an exhaust hood with air flowing over the top of the glass bottle at the rate of approximately 100 ft 3 /minute.
[0071] Sample 12: To a 10 gram sample of tung oil/Co drier was added 0.0760 grams of Solution K above (HQ/DiPAE in water). The solution was mixed in a glass bottle and placed in an exhaust hood with air flowing over the top of the glass bottle at the rate of approximately 100 ft 3 /minute.
[0072] Sample 13: To another 10 gram sample of tung oil/Co drier was added 0.0819 grams of Solution L above (MeHQ/DiPAE in water). The solution was mixed in a glass bottle and placed in an exhaust hood with air flowing over the top of the glass bottle at the rate of approximately 100 ft 3 /minute.
[0073] The results of the testing of samples A through L are summarized in Table 7.
TABLE 7 Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 Sample 6 Sample 7 Day 1 Skinned No Skin No Skin No Skin No Skin No Skin No Skin Day 2 Skinned No Skin No Skin No Skin No Skin No Skin No Skin Day 4 Skinned No Skin No Skin No Skin No Skin No Skin No Skin Day 5 Skinned Start of No Skin No Skin No Skin No Skin No Skin Skin Day 6 Skinned Start of No Skin No Skin No Skin No Skin No Skin Skin Day 7 Skinned Skinned No Skin No Skin No Skin No Skin No Skin Day 8 Skinned Skinned Start of No Skin No Skin No Skin No Skin Skin Day 9 Skinned Skinned Start of Start of Start of No Skin No Skin Skin Skin Skin Day 10 Skinned Skinned Skinned Start of Start of No Skin No Skin Skin Skin Day 11 Skinned Skinned Skinned Skinned Skinned Start of Start of Skin Skin Day 12 Skinned Skinned Skinned Skinned Skinned Skinned Skinned Sample 1 Sample 8 Sample 9 Sample 10 Sample 11 Sample 12 Sample 13 Day 1 Skinned No Skin No Skin No Skin No Skin No Skin No Skin Day 2 Skinned No Skin No Skin No Skin No Skin No Skin No Skin Day 4 Skinned Start of No Skin No Skin No Skin No Skin No Skin Skin Day 5 Skinned Start of No Skin No Skin No Skin No Skin No Skin Skin Day 6 Skinned Skinned No Skin No Skin No Skin No Skin No Skin Day 7 Skinned Skinned No Skin No Skin No Skin No Skin No Skin Day 8 Skinned Skinned No Skin No Skin No Skin No Skin No Skin Day 9 Skinned Skinned No Skin No Skin No Skin No Skin No Skin Day 10 Skinned Skinned Start of Skin Start of Skin No Skin No Skin No Skin Day 11 Skinned Skinned Start of Skin Start of Skin No Skin No Skin No Skin Day 12 Skinned Skinned Skinned Skinned Start of No Skin No Skin Skin Day 13 Skinned Skinned Skinned Skinned Skinned Start of Start of Skin Skin Day 14 Skinned Skinned Skinned Skinned Skinned Skinned Skinned Day 15 Skinned Skinned Skinned Skinned Skinned Day 16 Skinned Skinned Skinned Skinned Skinned Skinned Skinned
The data in Table 7 shows the efficacy of the combination of the present invention at controlling skin formation without adversely impacting dry through time. The data shows an oxygen scavenger and alkyl amine and/or alkyl alkanolamine can be dissolved in mineral spirits or water then added to the alkyd during manufacture of the resin to provide a resin with acceptable dry through ad controlled skin formation.
[0074] While the present invention has been described with respect to particular embodiments thereof, it is apparent that numerous other forms and modifications of this invention will be obvious to those skilled in the art. The appended claims and this invention generally should be construed to cover all such obvious forms and modifications which are within the true spirit and scope of the present invention.
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The invention relates to anti-skinning agents containing combinations of (a) organic or inorganic oxygen scavengers with (b) alkylamines and/or alkyl alkanolamines and also relates to compositions containing the combination, especially oxidatively drying paints or coating compositions and articles coated with such oxidatively drying paints or coating compositions.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to drilling and producing wells underwater and particularly to supporting a marine riser extending upwardly from the bottom of a body of water.
2. Description of the Prior Art
In recent years the search for oil and gas has extended into increasingly deeper waters. Economic considerations and physical limitations frequently militate against the use of bottom supported platforms in very deep water. Therefore, most offshore drilling and production in deep water is conducted from a floating drilling or production platform which supports the drill rig and derrick and associated drilling equipment and/or production equipment. A marine riser is normally used to interconnect the floating platform and the subsea equipment such as a wellhead located upon the seafloor.
A marine riser may be employed in offshore operations to (1) guide tools and components into a well being drilled and to circulate drilling fluids and cuttings; (2) to convey fluids and tools from a floating vessel and a subsea installation, (i.e., subsea well, template, manifold, etc.) The marine riser is presently regarded as the limiting element in floating drilling operations and/or production operations since the weight of the marine riser and the stresses within the riser increase with water depth. Adding to the stress on the marine riser are bending moments caused by the action of wind, wave and sea currents on the riser and by movements of the floating platform.
To counteract marine riser stress, riser tensioning devices are normally mounted on the floating drilling or production platform. These tensioning devices apply a tensile force to the top of the marine riser, thereby reducing bending stresses on the riser. The use of flexible joints placed at the ends of the riser has also been used to increase riser flexibility. However, both riser tensioning devices and flexible joints have limitations as to the amount of riser stress which they can relieve.
Riser tensioning systems may be divided into "active" and "passive" systems. Active riser tensioning systems using hydraulically-driven piston and cylinder tensioners or other means (i.e., elastomeric springs) are subject to mechanical failure. Such failure may cause the marine riser assembly to collapse, severely damaging the subsea equipment and/or causing an underwater blowout with subsequent pollution and risk of danger to the floating platform, its equipment and crew. As noted in other patents, a passive riser tensioning system may be employed to avoid the problems of an active riser tensioning system. One form of a passive riser tensioning system comprises at least one buoyant member, such as a buoyancy chamber, or shaped foam floatation sections attached near the upper end of the marine riser in order to apply upward buoyant force to the riser. Use of such buoyant members decreases the amount of tensioner equipment that must be carried by the floating platform and eliminates tension reaction forces from the vessel thus reducing the vessel's buoyancy requirements.
As shown for example, in U.S. Pat. No. 3,017,934 entitled "Casing Support" issued Jan. 23, 1962, to A. D. Rhodes et al, a series of buoyant members may be attached around the periphery of the marine riser in order to supply the upward buoyancy necessary to apply tension to the riser. As shown in patent '934 however, the buoyancy members or tanks terminate some distance below the floating platform. Maintenance on these buoyancy members requires that the marine riser be disconnected from the subsea equipment, or that underwater operations be conducted in order to repair and/or inspect the submerged members. Each buoyant member must also be attached in a tedious manner to the riser as the riser is being assembled and lowered downwardly to the subsea equipment.
Each time that it becomes necessary to inspect one of these buoyant members, production from the subsea equipment must be interrupted and the riser disconnected from the subsea equipment in order to allow the riser buoyant member(s) to be removed to the surface. Accidental or emergency disconnection of the riser from the subsea equipment would expose the floating platform positioned above the riser to damage from the upwardly surging riser, with attendant risk to the crew of the platform.
A method and apparatus therefore need be developed that allows a riser to be passively tensioned by a buoyant member, without the inherent disadvantages mentioned previously in the use of such a member. A method and apparatus need be developed that permits maintenance operations on such a member without disrupting normal use of the marine riser. Such a member must be capable of easy removal from the riser in order to simplify the removal and/or inspection process of the member. The member should also be capable of easy attachment to the riser as the riser is assembled and/or connected to the subsea equipment.
SUMMARY OF THE INVENTION
The apparatus of the subject invention comprises a buoyant member having a vertical slot defined longitudinally through a portion of the member. The slot is formed to allow the riser to be passed through this slot and subsequently centered relative to the center of buoyancy of the member. A landing shoulder formed about the upper portion of the riser contacts the upper surface of the buoyant member and thereby transfers the buoyancy of the member to the riser, or from the perspective of the member transfers the weight of the riser to the member. The buoyancy of the member may be fixed or optionally adjusted to apply any desired upward tension to the riser.
During transfer of the riser to the buoyant member slot, lift means carried by the floating platform supply an upward tension to the riser sufficient to position the riser's landing shoulder at least above the upper surface of the buoyant member. At the time that the riser is being positioned within the vertical slot and its weight subsequently transferred to the member, the riser may remain suspended downwardly from the lift means and not be connected to any subsea equipment located upon the seafloor. The buoyancy member may be in a fully raised position when the disconnectd riser is engaged with the member. In this case, the riser and component at its lower end must be heavier than the buoyancy provided in order to allow the riser to be lowered and connected.
Alternatively, the riser may be connected to subsea equipment at the time that the riser's weight is transferred from the lift means to the member. In this latter case to insure that the landing shoulder is positioned above the upper surface of the member, the member may be submerged a sufficient distance below the landing shoulder so that the upper surface of the member is located below the bottom surface of the landing shoulder.
In this manner the riser may be easily positioned within the buoyant member and by the addition of additional buoyancy to the member the member may then support the entire weight of the riser, the riser lift means subsequently being disconnected from the upper portion of the riser.
If it is desired to inspect or perform maintenance on the buoyant member the riser lift means may be connected to the top upper portion of the riser, and then the buoyancy of the buoyant member decreased sufficiently to sink the member a selected distance below the landing shoulder of the riser, in order to freely move the riser away from the buoyant member. Buoyancy may then be added to the buoyant member sufficient to surface the member for inspection and/or complete retrieval from the body of water for further inspection.
It is therefore an object of the present invention to provide an improved method and apparatus to support the weight of a riser suspended vertically from a floating platform downward through a body of water.
It is a further object of the invention to provide a passive riser tensioning apparatus that is easily inspected over the life of the floating platform. It is a further object of the present invention to provide a riser tensioning apparatus that is inherently safer and more economical to operate than the previously disclosed active riser tensioning systems which utilize pistons and hydraulic cylinders or other means to actively tension the upper end of a riser.
It is a feature of the present invention to use a buoyant member having a vertical slot defined longitudinally therethrough and positioned within a vertical opening defined through a floating platform and being capable of vertical movement therein, to support the weight of an elongated vertical marine riser, the marine riser provided with connection means at its lower end for connection of the lower end to subsea equipment fixedly anchored to the seafloor and landing shoulder means connected to the upper portion of the riser having an outer dimension greater than the width of the vertical slot of the buoyant member.
These and other features, objects and advantages of the present invention will become apparent from the following detailed description, wherein reference is made to the figures in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation in side view showing several steps in the process of supporting several marine risers from several buoyant members.
FIG. 2 is a schematic representation taken along lines 2--2 of FIG. 1 of a plan view of an array of buoyant members positioned radially outward from a central moon pool opening defined upwardly through the floating platform.
FIG. 3 is a schematic representation of a side view in partial cross section of a buoyant member shown supporting the weight of a marine riser.
FIG. 4 is a schematic representation of a plan view taken along lines 4--4 of FIG. 3 of the buoyant member positioned within a buoyant members' opening and aligned with a riser slot opening by means of vertical key guides positioned within key guide slot openings.
FIG. 5 is a schematic representation of a side view of a riser and buoyant member prior to commencement of maintenance operations on the buoyant tank.
FIG. 6 is a schematic representation of a side view of the riser removed from the buoyant member vertical slot and the buoyant member submerged within the buoyant member opening.
FIG. 7 is a schematic representation of a side view of the riser positoned within a vertical slot of an additional buoyant member, the original buoyant member being shown partially removed from the buoyant member opening.
FIG. 8 is a schematic representation of a plan view showing the path of movement of the riser from the original buoyant member to the additional buoyant tank.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 a floating platform 11 is shown floating upon the surface 12 of a body of water 13 having a particular seafloor 14. Marine risers 15A, B, C are shown depending downwardly from a vertical opening 16 defined upwardly through platform 11 to subsea equipment 17A, B such as a wellhead well known to the art, the lower end 18 of marine riser 15A provided with connection means 19A for connection of the riser to subsea equipment 17. Connection means 19B, C are also shown provided at the lower ends of marine risers 15B, C, respectively. Flexible flowlines 21 place the upper end of marine riser 15C in fluid communication with production equipment 22 carried by the floating platform 11. The flexible flowlines may be those manufactured for example by COFLEXIP INC. (23 Avenue de Neville, 75116 Paris, France) and allow the marine riser 15C to move relative to floating platform 11 while still maintaining a flow of fluids from the riser 15C to the platform 11 equipment 22. It should be well understood that whereas production equipment 22 is shown located upon the floating platform 11 the marine risers 15A- C may also be used for drilling operations or any other subsea operations well known to the art.
Riser assembly and support means 23, 23A comprising slips 24 used in conjunction with lift means 25, 25A such as a crane well known to the art are used during the assembly of risers 15A-C and also to support the weight of the risers 15A, B, and C.
Buoyant members 27A, B are shown in various stages used to support the weight of risers 15B, C, respectively. Landing shoulder means 28A, B, C such as an outwardly-extending flange well known to the art are shown connected to the upper portions 29A, B, C of risers 15A, B, C, respectively. In a preferred embodiment, these upper portions 29A, B, C may take the form of riser extensions 30A, B, C formed to carry the landing shoulder means 28A, B, C, and to readily connect portions of the riser assembly and support means 23, 23A to the upper portions 29A, B, C of risers 15A-C, though it is well recognized that standard marine riser 15A, B, C sections may also be modified to accomplish the same mechanical results.
Buoyant members 27A, B are shown positioned within portions of the vertical opening 16 which forms buoyant member openings 31A, B, respectively. Lower stop means 32A, B such as inwardly extending annular shoulders prevent buoyant tanks 27A,B from falling out of the buoyant tank openings 31A,B when the tanks 27A,B obtain negative buoyancy. Buoyancy adjustment means 34 such as a pump well known to the art with associated piping, is capable of adding buoyancy means to and/or removing buoyancy means from buoyant members 27A, B.
A guide cap assembly 35 is positioned over buoyant member opening 31B after buoyant member 27B supports the weight of marine riser 15C as explained in more detail later.
Referring now to FIGS. 1 and 2 the method of supporting the weight of an elongated vertical marine riser in a body of water by use of a buoyant member having a vertical slot 36A defined longitudinally downward through the member may be explained in further detail. As shown in FIG. 1 and by way of explanation marine riser 15A has just been assembled by the riser assembly and support means 23 and remains connected at its upper end 37A to lift means 25. The marine riser 15A can be seen to be positioned within the vertical opening 16 defined downwardly through the floating platform 11 and can be seen to be supported at its upper end 37A by a portion of the riser assembly and support means 23. Marine riser 15A is shown extending in tension substantially centrally down through the vertical opening 16 to a point adjacent the seafloor 14.
The method of support of the weight of risers 15A, B, C may be seen to comprise the steps of moving riser 15A towards and subsequently into the vertical slot 36A formed through the buoyant member 27A. For purposes of clarity, marine riser 15B is shown in this position in FIG. 1. After the riser 15B has been moved into vertical slot 36A buoyancy means such as a fluid having a positive buoyancy in water, or air, or any other gas well known to the art may be added from the buoyancy adjustment means 34 to the buoyant member 27A in a sufficient amount to increase the buoyancy of the member sufficiently to support the entire weight of the riser 15B. It should be well understood of course for the buoyancy member 27A to support the weight of riser 15B the landing shoulder means 28B connected to the upper portion of the riser 15B must have an outer dimension greater than the width 38 (FIG. 4) of the vertical slot 36A of buoyant member 27A.
More specifically, in a preferred embodiment the previous method may include, subsequent to the step of moving the riser 15 towards and subsequently into the vertical slot 36A formed through the buoyant member 27A, the additional steps of lowering the riser 15B by operation for example of lift means 25A, contacting the landing shoulder means 28B to the upper surface 39 (FIG. 3) of the buoyant member 27A, further lowering the riser 15B and the buoyant member 27A downwardly through the body of water 13, contacting the connection means 19B carried at the lower end 18 of the riser 15B to the subsea equipment 17A which is fixedly anchored to the seafloor 14, and thereafter connecting the connection means 19B to the subsea equipment 17A.
Prior to contacting the connection means 19 to the subsea equipment 17 it is realized of course that the connection means 19 must be positioned relatively centrally above the subsea equipment 17.
Depending upon the relative elevation of the landing shoulder means 28 relative to the buoyant member 27 in any particular assembly sequence it may be necessary to actuate the lift means 25 of the riser assembly and support means 23 a distance sufficient to lift the landing shoulder means 28 above the upper surface 39 of a particular buoyant member 15. As discussed later, if a buoyant member 27 is submerged to the bottom of the buoyant member opening 31, the previous two steps may not be necessary. In particular, if connection means 19 is already connected to subsea equipment 17 then a particular buoyant member 27 must be lowered below the elevation of a particular landing shoulder means 28 in order for the riser 15 to fit through that particular member's 27 vertical opening 36.
More specifically, the method of supporting the weight of a marine riser 15 may further include, prior to the step of moving the riser 15 towards a particular buoyant member 27, the following steps. The outer vertical surface of a buoyant member 27 may first be formed in the shape of an elongated member having a particular outer shape and dimension, such as a cylinder, by means well known to the art. The outer vertical surface of the buoyant member 27 may then be provided with at least one vertical key guide 41. The vertical opening 16 may be divided into a central moon pool opening 42 that a particular riser 15 may be assembled within. At least one riser slot opening 43 may be connected to the moon pool opening 42 having a width greater than the width of the upper end of a riser 15 but less than the outer dimension of a particular buoyant member 27. At least one buoyant member opening 31 may be connected to the riser slot opening 43, the buoyant member opening 31 having a dimension greater than the width of the riser slot opening 43 and formed to allow vertical displacement of a buoyant member 27 within the opening 31. At least one key guide slot opening 44 may be connected to the buoyant member opening 31, having a width greater than the width of the vertical key guide 41 and formed to allow vertical displacement of the vertical key guide 41 within the key guide slot opening 44.
Each buoyant member opening 31 with its associated riser slot opening 43 may be spaced in a radial manner about the central moon pool opening 42 or located in other positions about the floating platform 11 in order to allow a multiplicity of risers 15 to be supported by a corresponding number of buoyant members 27.
In a preferred embodiment then after dividing the vertical opening 16 into the above openings 42, 43, 31, and 44 the installation of each buoyant member 27 may be explained in more detail. Each buoyant member 27 may first be positioned centrally above its respective buoyant member opening 31. Lift means 25 may be used for this purpose. The vertical key guide 41 may then be aligned with the key guide slot opening 44 and thereafter the buoyant member 27 may be lowered downwardly into the buoyant member opening 31 and the vertical key guide 41 into the key guide slot opening 44. The key guide 41 and key guide slot opening 44 may be positioned relative to the riser slot opening 43 so as to align the vertical slot 36 of a particular buoyant member 27 with a particular buoyant member's riser slot opening 43.
Referring now to FIGS. 3 and 4 a particular buoyant member 27 supporting the weight of a riser 15 while moving vertically within buoyant member opening 31 of floating platform 11 is shown in more detail. Member 27 is positioned similar to member 27B shown in FIG. 1. It should be noted that after the landing shoulder means 28 contact the upper surface 39 of the buoyant member 27 and the weight of the riser 15 is subsequently transferred to the buoyant member 27, the member 27 will typically be fully immersed within the body of water 13 and therefore the guide cap assembly 35 may be placed about the upper portion of the riser above the landing shoulder means 28, the guide cap assembly 35 typically having an outer dimension greater than the outer dimension of the buoyant member opening 31, the guide cap assembly 35 carried at its lower end by the floating platform 11 and having a central opening 46 defined upwardly through the center of the assembly 35 thereof, the dimension of the opening 46 greater than the outer dimension of the upper portion of the riser 29. It is understood that the guide cap assembly 35 may be installed any time after the landing shoulder means 28 is lowered through the area that the guide cap assembly 35 will be positioned within.
The upper portion of the riser 29 of course is capable of vertical movement through the central opening 46 of the guide cap assembly 35. The guide cap assembly 35 may include roller means 47 such as rollers supported on bearings well known to the art connected to the guide cap assembly 35 and arranged circumferentially about the central opening 46. The roller means 47 are positioned so as to be rotatably engaged with the upper portion 29 of the riser 15 as the riser 15 moves relative to the floating platform 11 so as to center the riser 15 within the central opening 46. In this manner, the scuffing of the buoyant member 27 with a wear liner 49 that has been installed within the buoyant member opening 31 will be minimized.
It should be noted that the wear liner 49 may be fabricated and installed in such a manner that it may be replaced after incurring a sufficient amount of wear to cause abrasion to portions of the floating platform 11.
The buoyancy member 27 may be designed and fabricated to provide a fixed amount of buoyancy or it may have a certain amount of fixed buoyancy plus variable buoyancy. In a preferred embodiment, the buoyant member 27 is shown having at least one buoyancy chamber 50 capable of receiving air or gas from pump 51 which forms a portion of the buoyancy adjustment means 34. Addition or removal of buoyancy means such as air or any other suitable medium having a specific gravity less than that of water may be controlled by use of control line 52 connected to control valve 53 by other means well known to the art. Flexible conduit 54 such as a hydraulic line well known to the art is shown incorporated between control valve and guide cap assembly 35 in order to compensate for movement of the member 27 within the buoyant member opening 31. Vents 56 may be incorporated in the lower portion of buoyancy chamber 50 in order to allow the displacement of portions of the body of water 13 to and from the buoyancy chamber 50 as buoyancy means is added to or removed from the chamber 50.
In any event, the buoyancy adjustment means 34 should be capable of adding sufficient buoyancy means to the at least one buoyancy chamber 50 in order to allow the buoyant member 27 to support the entire weight of the riser 15.
It is well recognized that some form of buoyancy material 57 (i.e., polyurethane foam or syntactic foam) may be incorporated within buoyant member 27 in order to supply at least a minimum buoyancy to member 27 in the event of a failure of the buoyancy chamber 50 to supply at least a minimum buoyancy to member 27. Buoyancy members 27 may be; (1) evacuated metal or synthetic material tubes, (2) homogeneous buoyant material (i.e., foam, wood, etc.) or (3) combination of both. In this manner even if all buoyancy is lost from buoyancy chamber 50 the member 27 will not direct its entire structural weight upon the upper end of the riser 15. It should be well recognized of course that many different combinations of buoyancy chambers and/or syntactic foam may be used to accomplish the same mechanical result of supporting the weight of the riser 15. Buoyancy chamber 50 is shown at the upper section of member 27 in order to minimize the amount of hydrostatic pressure that must be overcome by the buoyancy adjustment means 34 in the process of forcing the buoyancy means within the buoyancy chamber 50. It should be well recognized also that the upper surface 39 of member 27 may be located above the surface 12 of the body of water 13 in order to position the control valve 53 above the surface 12, thereby minimizing its corrosion due to submersion within the body of water 13.
Flexible flowlines 21 are shown connected to flow control valves 65 which may take the form of well master control valves and associated flow choke valves well known to the art, used to control the flow of production fluids for example from the subsea equipment 17. As explained later, flexible flowlines 21 should be made long enough to allow movement of riser 15 from one buoyant member opening 31 to another.
Referring now to FIG. 4 it is well recognized that other vertical alignment means 58 may be incorporated between the member 27 and the floating platform 11 in order to maintain the vertical slot 36 of the member 27 properly oriented with respect to the riser slot opening 43. In a preferred embodiment the vertical alignment means 58 typically have a first and second portion, one of the portions of the alignment means 58 formed in the buoyant member 27 the other of the portions of the alignment means 58 formed in the floating platform 11 located adjacent the buoyant member 27. In the preferred embodiment shown in FIG. 4 the first portion of the vertical alignment means 58 comprises at least one vertical key guide 41 wherein the second portion of the alignment means 58 comprises at least one key guide slot opening 44 connected to the vertical opening 16 (FIG. 3), It is well recognized that many other various alignment means 58 may be used to accomplish the same mechanical result.
It must be remembered that in the discussion up to this point the method of supporting the weight of the riser comprised the general steps of moving a riser towards and subsequently into a vertical slot formed through a buoyant member and subsequently adding buoyancy means from buoyancy adjustment means to the buoyant members sufficient to support the entire weight of the riser. More specifically, in this discussion the lower end of the riser was not connected to the subsea equipment when the riser was moved within the vertical slot.
Referring now to FIGS. 5 through 8, however, the lower end of the riser 15 is shown connected to subsea equipment 17 fixedly anchored to the seafloor 14, before the riser 15 is moved within a buoyant member 27D. It should be well recognized that the lower end of the riser 15 may or may not be connected to its lower end 18 to subsea equipment 17 during the performance of the general steps of the method of the present invention.
Referring now to FIG. 5 it may be necessary at some point in time to perform maintenance operations on buoyant member 27. At this point in time the riser assembly and support means 23, previously disconnected from the upper portion of the riser 15 may be reconnected to the upper portion of the riser 15. The weight of the riser 15 may then be transferred to the riser assembly and support means 23. Buoyancy may then be removed from the buoyant member 27, which causes the member 27 to travel downward through the buoyant member opening 31 as indicated by arrow 59. Once the landing shoulder means are no longer carried by the buoyant member 27 the riser 15 may be moved from the buoyant member opening 31 as indicated by arrow 60. The riser 15 may be moved away from and subsequently out of the vertical slot 36B (FIG. 8) by use of the riser assembly and support means 23 if sufficient flexure exists along the entire length of riser 15 to allow movement of the upper portion of the riser 15 without requiring the movement of the floating platform 11. It is well recognized of course that the floating platform 11 may be moved relative to riser 15 to accomplish the same mechanical result.
Referring now to FIG. 6 upon removal of sufficient buoyancy from the buoyant member 27 the buoyant member 27 will sink downwardly through the body of water 15 until it is carried by lower stop means 32 provided at the lower end of the vertical opening forming the buoyant member opening 31. The lower stop means 32 prevent further downward movement of the buoyant member 27. The buoyant member 27 may be carried by the lower stop means 32 at least until the riser 15 has cleared away from the buoyant member opening 31.
Referring now to FIG. 7 sufficient buoyancy may now be added to the buoyant members 27 to allow removal of the member 27 from the buoyant member opening 31 which forms a portion of the vertical opening 16 (shown in FIG. 1). Lift means 25A (FIG. 1) such as a crane and hoist mechanism may be used to lift the member 27 from the buoyant member opening 31. The member 27 which forms the passive tensioning mechanism for the riser 15 may now have maintenance and/or inspection operations performed on the member 27 while production continues to flow from riser 15 through flexible flow lines 21. In any event, the key advantage of the use of this method is that the lower end of the riser need not be disconnected from the subsea equipment 17 in order to perform maintenance and/or inspection operations on the buoyant member 27. If the riser had to be disconnected each time that maintenance or inspection was required on a buoyant member 27 the resultant production from subsea equipment 17 would be lost sometimes for up to a period of one week, dependent upon the difficulty of reconnection of the lower end of the riser 15 with the subsea equipment 17. Each time that a disconnection and connection operation is conducted with the subsea equipment 17 the risk also exists that irreparable damage may result between both devices 17, 19 which would require full retrieval of a riser 15 from the body of water and subsequent underwater repair operations to be conducted upon the subsea equipment 17. The risk of this occurrence is eliminated by the use of the steps of this method.
While the buoyant member 27 is being inspected and/or subjected to maintenance operations the riser 15 may remain suspended from the riser assembly and support means 23, or alternatively in a preferred embodiment the riser 15 may be repositioned within an additional buoyant member 27D correspondingly having a vertical slot as before defined longitudinally downwardly through the member 27D, member 27D being similar to member 27. As shown in FIG. 7 the member 27D may be fully submerged and be carried upon the lower stop means 32 while the riser 15 is moved towards and subsequently into the vertical slot formed through the member 27D. Subsequent to locating the riser 15 within the slot additional buoyancy means may be added from the buoyancy adjustment means 34 (FIG. 1) to the member 27D sufficient to raise the member 27D upwardly through the buoyant member opening 31, into contact with the landing shoulder means 28 and sufficient to support the entire weight of the riser 15. At this point in time the riser assembly and support means 23 may be disconnected from the upper end of the riser 15.
Referring now to FIG. 8 the path of movement 62 of riser 15 is indicated by arrows 60, 61 also shown in FIGS. 5 and 7. It should be well recognized that riser 15 may be positioned within any additional buoyant member shown within the vertical opening 16 of FIG. 8. Note also that while a buoyant member 27 is removed from buoyant member opening 31 the well liner 49 (shown in FIG. 3) may be easily removed from the opening 31 for repair and/or inspection.
It should be recognized that the weight of the riser 15 may be supported either by the steps set forth schematically in FIG. 1 where the riser 15 is not initially connected to the subsea equipment 17, or alternatively the riser 15 may be installed upon a buoyant member 27 as shown in FIG. 7 where the lower end of the riser 15 is connected to the subsea equipment 17 prior to the riser 15 being supported by the buoyant member 27D.
Many other variations and modifications may be made in the apparatus and techniques hereinbefore described, both by those having experience in this technology, without departing from the concept of the present invention. Accordingly, it should be clearly understood that the apparatus and methods depicted in the accompanying drawings and referred to in the foregoing description are illustrative only and are not intended as limitations on the scope of the invention.
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A method and apparatus is set forth in the present invention for supporting the weight of a marine riser by use of a passive tensioning system which utilizes a buoyant member located upon the upper end of the riser. The member has a vertical slot defined through its side such that the riser may access the member from a lateral direction. Such lateral access of the riser to the member allows these buoyant members to be changed from beneath the riser when maintenance and/or inspection is required on a particular member.
Since the riser need only to move laterally to access any member, and the riser may be temporarily supported at the surface by other means, the lower end of the riser does not need to be disconnected from subsea equipment when maintenance and/or inspection operations are required on a buoyant member. Well operations do not need to be interrupted, therefore, during buoyant member maintenance operations.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an electrical connector and an electrical connector assembly, more particularly to an electrical connector and an electrical connector assembly having heat-radiating structures.
[0003] 2. Description of the Related Art
[0004] Electrical connectors are widely used today. In general, electrical connectors can be classified as desktop connectors, laptop connectors, mobile phone connectors, consuming connectors, and other types. Power connector is one common kind electrical connector used in different equipments. Usually, a plug-type power connector and a receptacle-type power connector mate with each other to supply power to equipments. Contacts of the plug and the receptacle contact one another to form electrical connection. However, because of impedance of contacts, heat is generated and is not easy to be radiated out of the connectors. If the heat cannot be radiated out of the connectors in time, the heat accumulated in the connectors may cause different problems. For example, contacting portions of the contacts may produce carbon, melt, and excessive deformation etc. The insulative housing also may produce deformation, melt etc. Such phenomenon all can produce influence to reliability of power transmission and use life of the power connectors.
[0005] Hence, it is disable to design an electrical connector to address problems mentioned above.
BRIEF SUMMARY OF THE INVENTION
[0006] Accordingly, an object of the present invention is to provide an electrical connector with improved heat-radiating structures.
[0007] Another object of the present invention is to provide an electrical connector assembly with improved heat-radiating structures.
[0008] In order to achieve the above-mentioned object, an electrical connector for electrically connecting with a complementary connector comprises an insulative housing defining a plurality of contact-receiving passages, and a plurality of conductive contacts respectively received in the contact-receiving passages adapted for electrically connecting with conductive contacts of the complementary connector and generating heat. The insulative housing defines a pair of first heat-radiating channels located at opposite lateral sides thereof and extending through the insulative housing along a mating direction, and at least one second heat-radiating channel extending through the insulative housing along the mating direction and located between at least a pair of contact-receiving passages adjacent thereto. The heat generated by the conductive contacts is capable of radiated out of the insulative housing through the first heat-radiating channels and the at least one second heat-radiating channel.
[0009] In order to achieve the above-mentioned object, an electrical connector assembly comprises a first connector and a second connector mating with the first connector. The first connector comprises a first insulative housing defining a plurality of contact-receiving passages, and a plurality of first conductive contacts received in the contact-receiving passages of the first insulative housing. The first insulative housing defines a pair of first heat-radiating channels located at opposite lateral sides thereof and extending through the first insulative housing along a mating direction, and at least one second heat-radiating channel extending through the first insulative housing along the mating direction and located between at least a pair of contact-receiving passages adjacent thereto. The second connector comprises a second insulative housing defining a plurality of contact-receiving passages, and a plurality of second conductive contacts received in the contact-receiving passages of the second insulative housing. The second insulative housing defines a pair of first heat-radiating passages located at opposite lateral sides thereof and extending therethrough along the mating direction, and at least one second heat-radiating passage extending through the second insulative housing along the mating direction and located between at least a pair of contact-receiving passages adjacent thereto. After the first and second connectors mate with each other, the first and second conductive contacts in electrical connection status generate heat. The first heat-radiating channels align with and communicate with the first heat-radiating passages. The second heat-radiating channel aligns with and communicates with the second heat-radiating passage. The heat generated by the first and second conductive contacts is capable of being radiated out of the first and second insulative housings via flowing through the first and second heat-radiating channels and first and second heat-radiating passages.
[0010] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter, which form the subject of the claims of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
[0012] FIG. 1 is an assembled, perspective view of a first connector (electrical connector) in accordance with the present invention;
[0013] FIG. 2 is a view similar to FIG. 1 , but viewed from a different aspect;
[0014] FIG. 3 is a cross-sectional view of the first connector taken along line 3 - 3 of FIG. 1 ;
[0015] FIG. 4 is an assembled, perspective view of a second connector (electrical connector) in accordance with the present invention;
[0016] FIG. 5 is a view similar to FIG. 4 , but viewed from a different aspect;
[0017] FIG. 6 is a cross-sectional view of the second connector taken along line 6 - 6 of FIG. 5 ;
[0018] FIG. 7 is an assembled, perspective view of an electrical connector assembly in accordance with the present invention;
[0019] FIG. 8 is a cross-sectional view of the electrical connector assembly taken along line 8 - 8 of FIG. 7 ;
[0020] FIG. 9 is a cross-sectional view of the electrical connector assembly taken along line 9 - 9 of FIG. 7 ;
[0021] FIG. 10 is an enlarged view of the circled part in FIG. 9 which illustrates the heat-radiating paths clearly;
[0022] FIG. 11 is a cross-sectional view of the electrical connector assembly taken along line 11 - 11 of FIG. 7 ; and
[0023] FIG. 12 is a cross-sectional view of the electrical connector assembly taken along line 12 - 12 of FIG. 7 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] In the following description, numerous specific details are set forth to provide a thorough understanding of the present invention. However, it will be obvious to those skilled in the art that the present invention may be practiced without such specific details. In other instances, well-known circuits have been shown in block diagram form in order not to obscure the present invention in unnecessary detail. For the most part, details concerning timing considerations and the like have been omitted inasmuch as such details are not necessary to obtain a complete understanding of the present invention and are within the skills of persons of ordinary skill in the relevant art.
[0025] Reference will be made to the drawing figures to describe the present invention in detail, wherein depicted elements are not necessarily shown to scale and wherein like or similar elements are designated by same or similar reference numeral through the several views and same or similar terminology.
[0026] Referring to FIGS. 1-3 , a first connector 1 in accordance with a preferred embodiment of the present invention is shown. In the preferred embodiment, the first connector 1 is a receptacle connector. As shown in FIG. 1 , the first connector 1 comprises a first insulative housing 2 and a plurality of first conductive contacts 3 assembled in the first insulative housing 2 . In the preferred embodiment, there are eight first conductive contacts 3 .
[0027] In the preferred embodiment, the first insulative housing 2 comprises a rectangular first base portion 21 and a first mating portion 20 extending forwardly from middle of a front surface of the first base portion 21 . A front surface 201 of the first mating portion 20 is of elliptic shape. Two rows of contact-receiving passages 22 in upper and lower relationship penetrate from the front surface 201 of the first mating portion 20 to a rear surface 210 of the first base portion 21 of the first insulative housing 2 . A pair of arc-shape protrusions 202 extends forwardly from opposite lateral sides of the front surface 201 and each forms a contacting surface 2020 for contacting with a second connector 4 . The arc-shape protrusions 202 also can be treated as being recessed from the front surface 201 of the first mating portion 20 .
[0028] Now, heat-radiating structures of the first connector 1 will be introduced in detail. The heat-radiating structures comprise a third heat-radiating channel 23 , and first and second heat-radiating channels 25 , 24 which respectively communicate with the third heat-radiating channel 23 . The third heat-radiating channel 23 is defined by the front surface 201 of the first mating portion 20 and the pair of protrusions 202 . The second heat-radiating channels 24 penetrate from the front surface 201 of the first mating portion 20 to the rear surface 210 of the first base portion 21 . In the preferred embodiment, there are three second heat-radiating channels 24 . If we define an upper contact-receiving passage 22 and a lower contact-receiving passage 22 as one group, then, each second heat-radiating channel 24 is located between two groups of aligned upper and lower contact-receiving passages 22 . Please refer to FIG. 2 in particular, each second heat-radiating channel 24 communicates with the four contact-receiving passages 22 of the two groups. The first heat-radiating channels 25 are of rectangular shape and penetrate from the contacting surfaces 2020 of the protrusions 202 to the rear surface 210 of the first base portion 21 . A slot 203 for preventing from mating wrongly with the second connector 4 is defined through the left lateral wall of the first mating portion 20 . A pair of standoffs 212 is formed on the rear surface 210 of the first base portion 21 and locates adjacent to upper and lower sides of the first heat-radiating channels 25 for supporting the first insulative housing 2 on a printed circuit board (not shown) and also for heat radiation.
[0029] In combination with FIG. 8 , each first conductive contact 3 comprises a first mating section 31 received in a front section of the contact-receiving passage 22 , a first retaining section 32 interferentially received in a rear section of the contact-receiving passage 22 , and a first mounting section 33 extending rearward from the first retaining section 32 and beyond the rear surface 210 of the first base portion 21 . Please refer to FIG. 2 , because the second heat-radiating channel 24 communicates with four adjacent contact-receiving passages 22 , the first retaining sections 32 of the first conductive contacts 3 are partially exposed into the second heat-radiating channel 24 . Therefore, better heat radiating effect can be achieved.
[0030] Referring to FIGS. 4-6 , the second connector 4 in accordance with a preferred embodiment of the present invention is shown. In the preferred embodiment, the second connector 4 is a plug connector. As shown in FIG. 4 , the second connector 4 comprises a second insulative housing 5 and a plurality of second conductive contacts 6 assembled to the second insulative housing 5 . In the preferred embodiment, there are eight second conductive contacts 6 .
[0031] The second insulative housing 5 comprises a rectangular second base portion 51 and a second mating portion 50 of elliptic-shape and extending from a rear surface of the second base portion 51 . The second insulative housing 5 defines two rows of contact-receiving passages 52 in upper and lower relationship which penetrate through the second base portion 51 . The second mating portion 50 comprises a mating surface 501 contacting the contacting surface 2020 of the first insulative housing 2 . A rib 502 is formed in the inner surface of a right side wall of the second mating portion 50 and extends along front-to-back direction for mating with the slot 203 of the first insulative housing 2 to prevent from wrong cooperation between the second and first connectors 4 , 1 .
[0032] Now, heat-radiating structures of the second connector 4 will be introduced in detail. The second connector 4 comprises a pair of first heat-radiating passages 55 and three second heat-radiating passages 54 . The second heat-radiating passages 54 penetrate through the second base portion 51 along front-to-back direction and each is located between two groups of aligned contact-receiving passages 52 (the group has the same meaning as in the first connector 1 ). The first heat-radiating passages 55 are located at left and right lateral sides of the second base portion 51 and penetrate through the second base portion 51 along front-to-back direction. A pair of ribs 550 is disposed in the second base portion 51 to separate each first heat-radiating passage 55 into upper and lower halves.
[0033] In combination with FIG. 8 , the second conductive contact 6 comprises a second mating section 61 exposed into the second mating portion 50 , a second retaining section 62 interferentially received in the contact-receiving passage 52 , and an L-shape second mounting section 63 extending from the second retaining section 62 and exposed beyond a rear surface of the second base portion 51 .
[0034] Please refer to FIGS. 7-12 , an electrical connector assembly 100 in accordance with the present invention is formed by mated first and second connectors 1 , 4 . What should be pointed out is the first and second connectors 1 , 4 are the electrical connectors in accordance with the present invention. When mated, the first mating portion 20 of the first insulative housing 2 is inserted into the second mating portion 50 of the second insulative housing 5 until the mating surface 501 of the second mating portion 50 abuts against the front surface of the first base portion 21 with the second mating sections 61 of the second conductive contacts 6 inserted into the first mating sections 31 of the first conductive contacts 3 to form electrical connection. Please refer to FIGS. 6-12 in particular, the electrical connector assembly 100 comprises a pair of first heat-radiating passageways 103 formed by the first heat-radiating channels 25 and the first heat-radiating passages 55 which are aligned with and communicate with one another, three second heat-radiating passageways 102 formed by the second heat-radiating channels 24 and the second heat-radiating passages 54 which are aligned with and communicate with one another, and the third heat-radiating passageway/channel 23 .
[0035] Therefore, after the first and second connectors 1 , 4 form electrical connection therebetween, the first and second conductive contacts 3 , 6 begin to product heat. The heat can be radiated to the outside in time (referring to arrow directions) through the first, second and third heat-radiating passageways 103 , 102 , 23 . The temperature of the first and second insulative housing 2 , 5 and the first and second conductive contacts 3 , 6 can be decreased effectively. Please refer to FIG. 10 , according to the directions indicated by the arrows, the heat flows from the third heat-radiating passageways 23 toward the first and second heat-radiating passageways 103 , 102 and is led out by the first and second heat-radiating passageways 103 , 102 . Please refer to FIG. 12 specially, since the contact-receiving passages 22 communicate with the second heat-radiating channels 24 partially, the heat generated by the first and second conductive contacts 3 , 6 also can be guided out from the contact-receiving passages 22 to the second heat-radiating channels 24 then to outside. At the same time, the first conductive contacts 3 partially exposed in the second heat-radiating channels 24 can be heat-radiated more effectively thus temperatures thereof can be decreased significantly.
[0036] The existence of these heat-radiating passageways 102 , 103 , 23 are capable of not only radiating heat effectively to prevent the insulative housings 2 , 5 and the conductive contacts 3 , 6 from producing different kinds of problems, but also assuring rigidity of the insulative housings 2 , 5 .
[0037] It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. For example, the tongue portion is extended in its length or is arranged on a reverse side thereof opposite to the supporting side with other contacts but still holding the contacts with an arrangement indicated by the broad general meaning of the terms in which the appended claims are expressed.
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An electrical connector for electrically connecting with a complementary connector includes an insulative housing defining a number of contact-receiving passages, and a number of conductive contacts respectively received in the contact-receiving passages adapted for electrically connecting with conductive contacts of the complementary connector and generating heat. The insulative housing defines a pair of first heat-radiating channels located at opposite lateral sides thereof and extending through the insulative housing along a mating direction, and at least one second heat-radiating channel extending through the insulative housing along the mating direction and located between at least a pair of contact-receiving passages adjacent thereto. The heat generated by the conductive contacts is capable of radiated out of the insulative housing through the first heat-radiating channels and the at least one second heat-radiating channel.
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RELATED APPLICATIONS
[0001] This application is a continuation in part and claims the benefit of U.S. application Ser. No. 09/652,235, filed Aug. 22, 2000, which claims the benefit of U.S. application Ser. No. 09/246,543, filed Feb. 8, 1999, now U.S. Pat. No. 6,185,862, issued Feb. 13, 2001, and U.S. application Ser. No. 08/832,384 filed on Apr. 2, 1997, now abandoned.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a device for capturing insects or other small pests. The invention further involves a method of use of the device which is particularly effective for the manual capture of insects when an individual is faced with a personal and proximate encounter.
[0003] Many, if not most, people have had experiences dealing with a personal encounter with insects or other pests where the insect is discovered either crawling on or near one's person. The presence of an insect or pests is particularly undesirable when found within one's home, automobile or other confined space. Common insects and other pests which are frequently encountered may include ticks, spiders, ants, flies, bees, wasps, scorpions, crickets, beetles and grasshoppers. Consumers would welcome a device which would enable them to catch and restrain such insects and pests without having to physically touch or handle the insects directly. Direct contact with such insects and pests is undesirable because they may bite or sting. Moreover, insects and pests may serve as carriers of disease or harmful germs. Brushing insects off or dropping the insect onto the floor is unsightly, does not restrain the insect and does not address the disposal problem. Swatting insects is often undesirable because the action will frequently leave a residue of the insect on the surface and also makes the disposal of the insect inconvenient. Furthermore, in circumstances where in the insect or pest is not resting on a hard surface, swatting the insect may not be effective. Swatting an insect may also leave a residue, such as blood, from the insect on the flyswatter which is also undesirable. The use of insecticides is likewise disfavored because of the hazardous nature of the chemicals used and the possible adverse health and environmental effects associated with pesticides.
[0004] According to the invention, insects are manually captured by attachment to a pressure responsive adhesive which has been provided on a pliable and compressible substrate in a sheet form. The sheet material has enveloping abilities which enables it to be folded over on itself so that a captured insect may be wrapped up and then appropriately disposed. The sheet according to the invention is constructed to be a convenient size for carrying and handling. After the insect is restrained and wrapped up in the sheet, it can then be conveniently and properly disposed of in the same manner as any other article of garbage. The insect may also be saved for inspection by a physician or other professional if there is concern that it is a poisonous or otherwise dangerous insect or pest.
[0005] The substrate can be made in a variety of sizes and configurations depending on the particular insect targeted. For example, in some parts of the country ticks are increasingly becoming a health problem, particularly in the Eastern United States. In this regard, certain ticks are potentially dangerous to humans and animals may carry harmful diseases including spotted fever and lyme disease. Often a user will want to be able to identify the species of the tick but there is no convenient and safe manner to trap and restrain the tick for further observation and identification by experts. Likewise, some regions of the United States experience heavy infestations of ants upon the change of seasons and, particularly in areas where food is prepared, the use of insecticides is undesirable. The substrate can thus be configured for the optimal capture of ants.
[0006] Accordingly, an object of the present invention is to provide a manually manipulated capturing device that employs pressure sensitive adhesive for the capture of insects or other small pests.
[0007] A further object of the invention is to provide a device which has an adhesive coated sheet with restraining capability only after the said adhesive portion of the sheet is pressed firmly against an intended insect, compressing and adhering the insect onto the adhesive.
[0008] A further object of the invention is to provide a manual insect capturing device which includes a pad of disposable stacked adhesive sheets with tabs allowing easy sheet separation, as intended insects are captured and restrained, the sheets being further used as a medium for wrapping the captured insect in preparation for its proper disposal.
[0009] A further object of the invention is to provide a manual insect capturing device that is absorbent and can collapse in response to the insects body thus reducing the smashing or squashing effect that occurs when an insect is sandwiched between a rigid article and a hard surface.
[0010] A further object of the invention is to provide the material or pad holder on the end of an elongate rod, such as a fly swatter handle, thereby providing a means for extension of the device's reach, greatly increasing the versatility of the device in the pursuit and apprehension of the intended insect or pest.
[0011] A further object of the invention is to provide means to post the manual insect capturing device in the user's home, car, or other convenient location.
[0012] Yet a further object of the invention is to provide a manual insect capturing device that can be conveniently carried by the user, in places such as pockets, backpacks and purses, enabling the device to be readily accessible for those times when, unexpectedly, insects are discovered crawling on or around ones person, their children or pets.
[0013] It is yet a further object of the invention to provide a manual insect capturing device that requires a minimum of skill and training to use and manipulate is inexpensive and effective.
[0014] A further object of the invention is to provide a manual insect capturing device that makes available a safe sanitary method for insect handling and disposal and to make the device available to the consumer in various sheet sizes and densities to accommodate different types, sizes and quantities of which are likely to be encountered by the user in their particular environment.
[0015] These and other various objectives and advantages of the invention will become apparent to the reader from a consideration of the following description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIG. 1 shows a perspective front view of a stack of adhesive coated sheets in accordance with the invention.
[0017] [0017]FIG. 2 shows a perspective view of the stack depicted in FIG. 1 with the top sheet being partially separated from the stack held by a user.
[0018] [0018]FIG. 3 is side sectional view of a single sheet such as that shown in FIG. 1 taken along line 3 - 3 .
[0019] [0019]FIG. 4 shows a perspective front view in elevation of a second embodiment of the invention having a corrugated design.
[0020] [0020]FIG. 5 shows a perspective view of a singular sheet made in accordance with the invention in use, with the tacky adhesive portion facing down shown making adhesive contact with a wood tick.
[0021] [0021]FIG. 6 shows a perspective view of such a sheet made in accordance with the invention folding over a restrained insect.
[0022] [0022]FIG. 7 shows an exploded view of the assembly of a stack of adhesive sheets and their integration with a pad holder on the end of a flyswatter.
[0023] [0023]FIG. 8 shows a perspective view of the assembly depicted in FIG. 7 on the handle of a flyswatter positioned above targeted insects.
[0024] [0024]FIG. 9 shows a perspective view of such a stack of sheets according to the invention, showing the initiation of the folding of a sheet and over the apprehended insects.
[0025] [0025]FIG. 10 is a sectional view in elevation of a sheet according to the invention.
[0026] [0026]FIG. 11 is an enlarged sectional view in elevation of the sheet depicted in FIG. 10.
[0027] [0027]FIG. 12 is a top view of a further embodiment of the invention.
[0028] [0028]FIG. 13 shows a top view of a further embodiment of the invention.
[0029] [0029]FIG. 14 shows a side view in elevation of the embodiment of the invention shown in FIG. 13.
[0030] [0030]FIG. 15 shows a side sectional view of a further embodiment of the invention in engagement with an insect against a hard surface.
[0031] [0031]FIG. 16 shows a top view of another embodiment of the invention.
[0032] [0032]FIG. 17 shows a side sectional view of the embodiment of the invention depicted in FIG. 16 wherein a compressible material is shown as the upper leading surface of the device and the adhesive coated surface is inset or recessed therein.
[0033] [0033]FIG. 18 shows a top view of another embodiment of the invention.
[0034] [0034]FIG. 19 shows a side sectional view of the embodiment of FIG. 18 wherein the adhesive surface is inset within a compressible material.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] Referring now to FIG. 1, a pad of adhesive sheets generally designated by the reference numeral 28 is shown. In this first embodiment each sheet is approximately {fraction (1/16)} inch thick and comprised of a low density paper substrate 22 . As best seen in FIG. 2 sheet 22 has an upper surface 30 and a lower surface 26 . Displaced upon a region of upper surface 30 is an adhesive 24 which has similar properties to those adhesives found on conventional clear cellophane tapes.
[0036] The range of adhesives generally acceptable for use with the invention are similar to those found on conventional Post-it brand tabs manufactured by 3M Company to those found on conventional masking tapes. The preferred contemplated adhesives include those pressure sensitive which form a bond on contact. Adhesives which could be effectively used in accordance with the invention have tackiness properties that range from those used in on conventional masking tape to those on the post it notes and accordingly the bond sought is not required to be particularly strong or permanent. As best seen in FIG. 1 the regions 30 devoid of adhesive on the top surface of the sheets are provided along a least two peripherial edges so that the sheet may be easily manipulated without adhering to the users hands. Preferably the region devoid of adhesive is located on opposite sides of the sheet as illustrated in FIG. 1. Providing such areas allows the users to easily separate the sheets as seen in FIG. 2. and, when in use, provides an area which will not adhere to the surface which is contacted by the adhesive, facilitating the removal of the sheet from the surface. When used, sufficient force is applied to the adhesive pad to merely engage the insect. The user tries to avoid application of significant force on surface which the insect is found and thereby tries to avoid a strong bond between the surface and the adhesive. The presence of the trapped insect between the substrate and the surface further serves to minimize the contact between the adhesive and the surface and accordingly the bonding between the adhesive and the surface is diminished. Substrate 22 is comprised of a low density, hydrophillic paper made of a porous mesh fiber construction which is rigid enough to support its own weight when held by region 30 .
[0037] [0037]FIG. 4 depicts a further embodiment of the invention where the substrate is comprised of a corrugated fiber material. The use of corrugation serves as an alternative manner in which to provide a compressible substrate. The use of this configuration also may provide an increased frictional engagement on the insect. Like the previous embodiment an adhesive is provided on a portion of one side of the substrate. It is contemplated that the adhesive would be placed in the depressed regions or crevices formed by the corrugated material. In this embodiment the device would be less likely to firmly adhere to the surface on which the insect is found, yet, adhesive within the crevices formed by the corrugation would still effectively engage the insect, or portions of the insect.
[0038] [0038]FIGS. 10 and 11 shows a further embodiment of the invention with a wax paper cover 110 or other similar non-porous non-stick sheet placed on top of the adhesive which seals the adhesive preventing it from drying out, protects the adhesive and prevents it from adhering to extraneous matter until the sheet is ready for use. In this embodiment the devices is provided to the user is the form of individual sheets. When the device is provided in the pad embodiment as disclosed as FIG. 1, a non-stick coating can be provided on the bottom side 26 of each sheet which serves this same purpose. The non-stick coating may also be provided in the form of a laminate layer.
[0039] [0039]FIG. 12 depicts a top plan view of a further contemplated embodiment where the profile of the device is circular rather than a square. In this embodiment the lateral region 113 and 114 are devoid of the adhesive and the adhesive is provided in a series of stripes across the top surface rather than being dispersed throughout the entire central adhesive region. By providing the adhesive on the substrate in this manner the adhesive does not significantly interfere with the hydrophilic properties of the substrate. Application of the adhesive to only a portion of the surface of the substrate is nevertheless effective at restraining an insect and conserves the amount of adhesive required. FIG. 13 shows another embodiment of the invention, in this embodiment the region devoid of adhesive 16 is provided around the entire periphery of the device. A best seen in FIG. 14, this area is on a laminate layer 121 and not provided on the hydrophillic compressible substrate 117 which is essentially coextensive with the adhesive areas. Like the embodiment set forth in FIG., 12 , the adhesive 118 does not completely cover substrate 117 but rather is provided in the form of small circular regions. Although the distribution of the adhesive has been disclosed as stripes and circular regions, it is contemplated that the adhesive may be provided in a wide variety of manners which would not effect the performance of the device. For example, it is contemplated that the adhesive could be provided in the form of a grid, checkerboard, or in small droplets and only dispersed across the surface of the substrate.
[0040] [0040]FIG. 15 shows yet another embodiment of the invention in engagement with an insect 130 and between a hard surface 132 such as a floor or wall. In this embodiment air cavities 134 are distributed throughout the substrate 138 which enables the substrate to be compressed in response to force applied from the bottom surface 142 of the device. The substrate has an adhesive layer 136 formed by application of droplets across the top surface. The matrix is made of a low density paper or cellulose and is hydrophillic. It is contemplated that other materials could also be satisfactorily be employed such as synthetic resins and when such synthetic resins are employed the resiliency feature of the substrate is enhanced. This embodiment is provided with a third layer 140 to increase the rigidity of the substrate. In this embodiment the device is made of thin cardboard having rigidity analogous to that of a conventional index card.
[0041] It is contemplated that alternative materials may be sued as the compressible substrate such as synthetic resin which is partially elastic and compressible or can collapse across an axis perpendicular with the planar surface on which is provided the adhesive.
[0042] The rigidity feature must be sufficient to allow a user to apply pressure from the opposite side of the substrate to crush and capture the insect. The device should preferably have a rigidity at approximately equal to that of the cardboard used in conventional commercially available index cards. Because the substrate is relatively thick compared to conventional paper, there is a more substantial barrier to between the insect and the individual using the material which serves to protect the user. In the embodiment the protective barrier is further enhanced by layer 140 . Thus when the intended target is a bee, wasp or other biting or stinging insect, the material used for the sheet is thick enough to prevent the user from harm.
[0043] A further feature of the invention, related to the thickness and compressibility of the substrate, is the ability of the substrate to absorb liquid residue from the insect. Any liquid from the insect or pest can be adequately absorbed by the material and any residue which may remains of the surface where the insect had landed is minimized. In this regard the substrate in each of the embodiments is made of a hydrophillic material. Because the presence of adhesives on the surface of the substrate may interfere with this feature of the invention, in order to optimize this feature, in some of the preferred embodiments the adhesive is intermittently applied over the surface of the substrate, rather than in a continuous coating so that a portion of the underlying substrate remains exposed.
[0044] The ability of the substrate to be compressed serves to increase the total surface area between the insect and the adhesive coated surface and the insect can therefore be more effectively trapped and restrained.
[0045] A further feature of the invention is the ability of the substrate to fold over upon itself. Accordingly, each of the substrate describe herein has pliable characteristics which enable a user to easily fold the substrate over upon itself to envelope the insect or pest therein. The substrate is maintained in a closed position by the engagement of the opposite adhesive surfaces contacting one another. Folding the substrate up increases the contact area between the adhesive and the insect and serves to further prevent the possibility that the pest may free itself from the adhesive. Folding the substrate essentially encapsulates the pest within the adhesive and will ensure that it cannot escape.
[0046] In the contemplated preferred embodiments the sheets are opaque which serves to obstruct and minimize the viewing which is a desirable feature in circumstances where the individual using the device has a fear of insects or when the crushed insect is unsightly. It is further contemplated that the devices can be provided with appealing graphics, educational information relating to insects or information relating to the method of use.
[0047] The use of the device involves application of the adhesive to an insect crawling along surface. The portion of the substrate provided with adhesive is pressed against the insect as shown in FIG. 15. Application of pressure causes the insects body to create a small depression or cavity within the substrate and increases the total surface areas between the adhesive agent and the insect. When the substrate is then is then removed from the surface the insect will adhere to the adhesive substrate. Because in most instances the targeted insects will have significantly less mass than the surface on which it is crawling, and the insect will generally have a higher affinity to the adhesive than a smooth flat surface. Likewise, the substrate is particularly useful to engage and capture the an insect found on the skin of a person as shown in FIG. 5 because the adhesive will generally have less adhesion to the skin of an individual dues presence of oils on the body. In FIG. 5 a substrate 22 , and more particularly the adhesive portion 24 is applied over tick 26 which was located on the hand of a user. Upon removal of the substrate from the surface the insect will be retained by the adhesive. Next, as shown in FIG. 6, the entire device is folded in half and the adhesive which remained exposed is allowed to engage itself and completely encapsulate the pest or insect. If the application of the pressure on the insect during the initial capture phase was not sufficient to kill the insect or pest, the further pressure can be applied to ensure the insect is indeed dead.
[0048] In each of the embodiments the device is engineered so that when pressed against the body of an insect, when on a hard surface such as wood, plaster or concrete, the substrate will generally conform to the body of the insect when pressure is applied to the insect from the bottom side devoid of adhesive. In alternative embodiments the bottom side of the device is provided with an additional material to further provide rigidity to the rear surface which increases the protective barrier. Preferably the bottom side of the substrate is water proof or water resistant and this feature will prevent any liquid residue from the crushed insect from migrating through the substrate from the to side to the bottom side where the surface is engaged by the hand, or could leak through to the next sheet. This feature maintains a barrier which ensures that the individual does not come into direct contact with the residue of the insect and, in connection with the pad embodiment keeps the next substrate in new condition.
[0049] In a further embodiment of the invention, the substrate is provided in combination with a conventional flyswatter or other elongate handle. Providing the substrate in combination with a flyswatter is useful for engagement of insects or pests which have been initially killed by flyswatter head and then must be disposed. The device may further be used as an alternative to a flyswatter in circumstances were the use of a flyswatter is not possible due to the location of the pest or when the insect is slow moving and a flyswatter is not required on. As seen in FIG. 8, in this embodiment a pad consisting of a plurality of the substrates such as described in FIG. 1 is combined with rigid support member 50 . Rigid support member 50 serves the purpose of the rigid support provided individually on the sheets as shown as a laminate layer 140 in FIG. 15. Support member 50 is attached to rod 52 , in this case, the opposite end or handle end of a conventional flyswatter. The device may be operated using a stamping action on the insects crawling on surfaces when it is not necessary to employ the speed of flyswatter head or in circumstances where there is insufficient room to swing the flyswatter head. Rod 52 serves to provide distance between the user and the target insect and accordingly serves to alleviate fear in those persons who have an aversion to insects. Providing the substrate on also makes the use of the device more convenient when the targeted insect is found crawling on the floor. The device as depicted in FIGS. 7 - 9 is particularly useful and effective for picking up ants and flying insects which have been killed by a flyswatter and have subsequently dropped to the floor. Combining the product with the flyswatter further results in a convenient, effective and multipurpose pest control and disposal tool. The pad 28 , as shown in FIG. 7 is adhered to the support member 50 by an adhesive 51 . In other contemplated alternative embodiments the substrate is held in place by mechanical means such as a frictional engagement, such as a tongue and groove arrangement or, the pad can be provided with a base which can be snap fit into a complimentary flange structure provided on holder 50 .
[0050] The manual insect capturing device of FIG. 1 can be used to capture a wide variety of insects, large and small. The device is easy to carry. The user will find this device useful when exposed to the habitats of annoying insects such as wood tics, but it will be equally useful attached to the handle of a fly swatter. The said attachment enables device extension from the user's hand as shown in FIG. 8 augmenting manual manipulation, greatly increasing device versatility, reaction time and speed during pursuit and apprehension of an insect.
[0051] In operation, the user optionally separates the top sheet 22 from its stack 28 . The operator then places the tacky portion 24 directly over the intended insect 26 and makes contact. The user then causes further compression on the insect allowing the adhesive to engage the insect. The adhesive catches and holds the insect. Next the adhesive coated material is folded over to envelope the insect and the insect is ready for proper disposal.
[0052] In an alternative embodiment shown in FIG. 7 the user employs the device by adhesion attachment onto a pad holder 50 connected to the end portion a fly swatter's handle 52 or other appropriate device which serves as a means of extension for amplification of manual manipulation of the device 28 whereby the user repeats the process of compression adhesion, capturing and restraining and disposing of the intended insect.
[0053] [0053]FIGS. 16 and 17 depict yet another embodiment of the invention wherein an adhesive layer 841 is provided on the top surface 850 of lower sheet substrate 860 . The lower surface may be comprised of conventional fiberboard. On top of the adhesive layer is provided a compressible and absorbent material 852 . FIGS. 18 and 19 depict yet another embodiment, similar to that illustrated by FIGS. 16 and 17, however the lower sheet substrate 900 has a portion extending therefrom that forms the leading surface 921 of the material. In this embodiment, it is apparent that both the sheet substrate and the extension areas 907 are made of the same compressible, and preferably absorbent, material. In this embodiment the extension area 907 defines a plurality of recessed areas that receive the adhesive material 950 . In the examples depicted in FIGS. 16 - 19 , it is evident that the adhesive is set within recessed cavities with respect to the leading surfaces 821 and 921 of the respective devices. While in FIGS. 18 and 19 the applicant has disclosed recessed circular areas other shapes are also contemplated, including but not limited to squares, triangles, rectangles or non-geometric shapes. Further, while the embodiment illustrated in FIGS. 16 and 17 depicts an adhesive central layer with a series of compressible materials in an elongate parallel orientation, it is contemplated that other arrangements may be made in accordance with the invention such as circular pads, triangular shaped pads or non-geometric arrangement. Further, although the invention illustrated herein comprises discrete pads that may be used to restrain a pest, it is contemplated that the material may be provided in a long rectangular section that may be rolled up. By providing the adhesive in a recessed area as described, the device is less likely to engage and stick to unintended planar environmental surfaces. Because the pest that is targeted by the device is elevated from the environmental surface, it may be more easily engaged by the recessed adhesive layer after the user applies pressure to the rear sheet substrate surface. In the embodiments depicted in FIGS. 16 - 19 , pressure is applied by the user against rear surface 960 and the absorbent and compressible material 865 comprises the leading surface 821 or 921 . Continued application of pressure to the rear device causes the compressible material to be displaced and the adhesive layer may then engage the target materials, such as the insect or pest. The embodiments depicted in FIGS. 18 and 19 are used in a similar manner; however, as shown, both the leading surface and the rear planar surface are made from the same materials that are both absorbent and compressible.
[0054] It is contemplated that additional variations of this invention may be made without departing from the principle thereof, and I do not wish to be understood as limiting myself to the specific construction shown and described herein. Those who are skilled in the art will envision many other possible variations still within its scope. For example, the means by which the enveloping of an insect's body mass takes place could be accomplished not only by a sheet, but through a variety of methods using elastic materials, fabrics, plastics or rubbers in place of the paper sheet, also mixing elastic material with the adhesive that coats the sheet. The sheet construction is a singular method of envelopment with many potential variations. For example, one may be constructed with a singular pocket, multiple pockets or elongated pockets—all of which are formed, impression constructed. Variations could occur in the density and thickness, multiple material layering, or trapping air pockets, all of which allow insect body mass and sheet to conform to one another as a result of compression of the void space within the sheet. The shape of the sheet could be elongated to that of a strip or a roll. Insect poisons and/or anti-bacterial agents could be added to the adhesive of the sheet. Different cover methods could be added to protect the device sheet and adhesive prior to use. Accordingly, the reader is requested to determine the scope of the invention by the appended claims and their legal equivalents, and not by the examples which have been given.
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A device for manually capturing and restraining intended insects, the same comprising a pad of stacked, singular sheets each sheet having a partial enveloping means comprised of hydrophillic absorbing material and collapsible sheet construction whereby the sheet partially conforms in response to the insects body mass. Each sheet has a region is coated with a mild compression adhesive material capable of trapping of an insect in response to the physical manipulation by a human being. The pad of stacked adhesive sheets can be used by separating each sheet individually or as a stack. Upon apprehension of an insect, the sheet restraining the insect is separated, if not already separated from its stack, folded to encase the insect and ready for disposal. The pad of stacked adhesive sheets can have various sheet sizes, thickness and density with varying enveloping ability—all depending upon intended insect to be trapped. For increasing the maneuverability of the device, the device can be attached to an elongated rod such as a fly swatter's handle.
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This is a continuation application of U.S. Ser. No. 08/495,165, filed Jun. 27, 1995, now U.S. Pat. No. 5,737,742.
BACKGROUND OF THE INVENTION
The present invention relates to memory systems using a flash memory, and more particularly to a memory system which attaches importance to its service life and response performance.
Flash memories are non-volatile like read only memories (ROMs) and also semiconductor memories from and into which data is readable and writable, respectively, like random access memories (RAMs).
The flash memories have the following limitations in use which the static RAMs (SRAMs) and dynamic RAMs (DRAMs) do not have:
(1) The unit of erasure is not a bit or byte, but a sector or chip;
(2) There is a limitation in the erasure count; and
(3) Erasure and write processes take a few milliseconds.
Unexamined published Japanese Patent Application JP-A-5-27924 discloses the following method to solve the limitations (2) and (3) of the flash memory:
In an embodiment of the present invention to be described later, the use of a flash memory in which data is erasable in units of a sector is assumed. Thus, only that portion of the prior art involved in the erasure of data in units of a sector will be described next.
First, addressing is made by mapping logical addresses designated by a host computer and physical addresses in a semiconductor memory.
When an erasure command is input before a write command, data in the sector concerned is nullified and its erasure starts in the background.
When a write command is input, it is written into a sector in which data is to be written, selected previously in consideration of its erasure count from among all free sectors.
Unexamined published Japanese patent application JP-A-5-241741 discloses a method of controlling the flash memory, but does not consider erasure of data in units of a sector.
Since in the prior art a sector which is not designated by an erasure command remains unerased, the erasure count varies from sector to sector, disadvantageously. Since the situation of access is not considered, a logical address having a strong probability of being written in the future can be allocated to a sector having a larger erasure count. Thus, the erasure count varies further from sector to sector, so that the whole storage using the flash memory would have a reduced lifetime. That is, since the flash memory has an upper limit of erasure count, the lifetime of the whole memory is limited by a physical block having a larger erasure count. Thus, in order to increase the lifetime of the whole memory, the erasure counts of the respective physical blocks are required to be nearly uniform.
Since in the prior art the erasure counts of many sectors are required to be known to determine a sector in which data is to be written, which takes much time.
SUMMARY OF THE INVENTION
It is therefore a first object of the present invention to provide a memory system using a flash memory which includes a plurality of physical blocks of one-several sectors erasable in units of a sector and nearly uniform in erasure count to thereby prolong the lifetime of the memory system.
A second object of the present invention is to provide a memory system using a flash memory capable of determining a physical block to be allocated to a logical block in consideration of a possible access situation in the future with the memory system being erasable in units of a sector.
A third object of the present invention is to provide a memory system using a flash memory capable of retrieving at high speed a physical block in which data is to be written with the memory system being erasable in units of a sector.
In order to achieve the above objects, the present invention provides a method of controlling a memory system connected to a host device, using a flash memory wherein a logical block as a unit accessed by the host device is allocated to a physical block of the flash memory. In the method, the following steps are performed: a write count or frequency of each logical block unit is counted and managed each time data is written into that logical block. An erasure count of each physical block unit is counted and managed each time that physical block is erased. A plurality of logical blocks is classified into a plurality of logical block groups according to write count. A plurality of physical blocks is classified into a plurality of physical block groups according to erasure count. A logical block belonging to a logical block group having a larger write count is allocated to a physical block which belongs to a physical block group having a smaller erasure count when data is written into the logical block.
The present invention also provides a memory system connected to a host device (for example, a computer), using a flash memory where logical blocks each as a unit accessed by the host device are allocated to physical blocks of the flash memory, the memory system including a flash memory having a plurality of individually erasable physical blocks; table means for holding the relationship in correspondence between the logical blocks allocated by the allocation means and the physical blocks; means for counting and managing write counts of the respective logical blocks; means for classifying the logical blocks into a plurality of groups on the basis of the respective write counts of the logical blocks; erasure means for erasing data in a physical block allocated to a logical block to produce a free physical block; means for counting and managing the erasure counts of the respective physical blocks; means for classifying the physical blocks into a plurality of groups on the basis of the respective erasure counts of the physical blocks; control means for allocating the respective logical blocks to the physical blocks; and means for managing free physical blocks which are not allocated to any logical blocks. The allocation control means performs an exchanging process which comprises the steps of allocating a logical block belonging to a logical block group having a larger write count to a free physical block belonging to a physical block group having a smaller erasure count and allocating a logical block belonging to a logical block group having a smaller write count to a free physical block belonging to a logical block group having a larger erasure count.
According to the present invention, if a logical block having a larger write count (or frequency) corresponds to a physical block having a larger erasure count, and if a logical block having a smaller write count corresponds to a physical block having a smaller erasure count, possible uneven erasure counts among the respective physical blocks are suppressed by changing an allocating or mapping relationship such that a physical block having a smaller erasure count is allocated to a logical block having a larger write count and that a physical block having a larger erasure count is allocated to a logical block having a smaller write count.
As a result, erasure counts of the respective physical blocks are nearly equalized, so that the lifetime of the whole storage system using a flash memory is increased.
By using a group table which designates a queue of physical blocks belonging to a respective one of at least one logical block group corresponding to each physical block group for this group, required information is acquired rapidly when a physical block is exchanged (in an exchange write process in the embodiment to be described later). Thus, the physical block to be allocated is retrieved rapidly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a block diagram indicative of an illustrative construction of a memory system using a flash memory as a first embodiment of the present invention;
FIG. 2 illustrates the relationship in correspondence be teen logical and physical spaces;
FIG. 3 illustrates the concept of a physical block group;
FIG. 4 illustrates the concept of a logical block group;
FIG. 5 Illustrates a logical block table and its entry, corresponding to a first embodiment;
FIG. 6 illustrates a physical block table and its entry;
FIG. 7 illustrates a free physical block table, group table, its entry and group queue.
FIG. 8 is a flow chart indicative of a read process;
FIGS. 9A and 9B illustrate the concept of a normal write processes;
FIGS. 10A and 10B illustrate the concept of an exchange write process;
FIG. 11 is a main flow chart indicative of a write process corresponding to the first embodiment;
FIG. 12 is a flow chart indicative of a physical block group structure changing process;
FIG. 13 is a flow chart indicative of a logical block group structure changing process;
FIG. 14 is a flow chart indicative of a logical block group moving process;
FIG. 15 is a flow chart indicative of a physical block group moving process;
FIG. 16 is a flow chart indicative of a normal write process corresponding to the first embodiment;
FIG. 17 is a flow chart indicative of an exchange write process corresponding to the first embodiment;
FIG. 18 is a block diagram indicative of an illustrative construction of a memory system using a flash memory as a second embodiment of the present invention;
FIG. 19 illustrates a logical block table and its entry, corresponding to the second embodiment;
FIG. 20 Illustrates a free physical block table, group table, its entry and group queue, corresponding to the second embodiment;
FIG. 21 is a main flow chart indicative of a write process corresponding to the second embodiment;
FIG. 22 is a flow chart indicative of a process for determining a physical block in which data is to be written;
FIG. 23 is a flow chart indicative of a normal write process corresponding to the second embodiment;
FIG. 24 is a flow chart indicative of an exchange write process corresponding to the second embodiment;
FIG. 25 is a flow chart indicative of an erasure process; and
FIG. 26 illustrates a table stored in a flash memory.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment of the present invention will be described in more detail next with reference to the accompanying drawings.
FIG. 1 shows the structure of a memory system 1000 as a first embodiment of the present invention. The memory system 1000 is connected to a host computer 1010, and includes a host interface 1020 which transmits/receives data to/from the host computer 1010, central processing unit (CPU) 1050, ROM 1040 which contains a control program of the present invention, RAM 1030 which holds a table necessary for control and functions as a buffer for data, and a flash memory 1060 which stores data.
FIG. 2 shows the relationship in correspondence between a logical block space accessed from the host computer 1010 and a physical block space of an actual flash memory 1060 in the memory system 1000. The physical block space is composed of normal physical blocks 1110 corresponding to logical blocks 1100 in one-to-one relationship, and free physical blocks 1120 which have no corresponding logical blocks 1100. The logical blocks 1100 and the physical blocks 1110 are placed in a corresponding relationship by a logical block table 1400 which will be described in more detail later with all the logical blocks 1100 having corresponding physical blocks 1110. All the physical blocks 1110 are classified according to erasure count, and compose a physical block group in dependence on the range of an erasure count. Each physical block is composed of one to several sectors.
FIG. 3 shows the concept of a physical block group 1200 (physical blocks 1210-1270). The axis of abscissas shows an erasure count of a physical block 1100 while the axis of ordinates shows the number of physical blocks 1110 belonging to each group. The physical blocks 1110 are grouped according to reference erasure count "m" which is a multiple of 1,000 and which satisfies a condition "m≦average erasure count<m+1,000" (in FIG. 3, m which satisfies the above condition is 3,000) into a physical block group A1210 of physical blocks 1110 having erasure counts of 0 to m-2,001, physical block group B1220 of physical blocks 1110 having erasure counts of m-2,000 to m-1,001, physical block group C1230 of physical blocks 1110 having erasure counts of m-1,000 to m-1, physical block group D1240 of physical blocks 1110 having erasure counts of m to m+999, physical block group E1250 of physical blocks 1110 having erasure counts of m+1,000 to m+1,999, physical block group F1260 of physical blocks 1110 having erasure counts of m+2,000 to m+2,999, and physical block group G1270 of physical blocks 1110 having erasure counts of m+3,000 or more. The average erasure count is included in the physical block group D1240 in dependence on the definition of m.
In the present embodiment, assume that the limit of the erasure count of the flash memory 1060 is, for example, a million. At this time, the erasure counts of the physical block 1110 can take a value of 0-999,999. Each of divisions of this range of erasure count by 1000 is referred to as an erasure count group 1280. The physical block groups B1220-F1260 have corresponding consecutive erasure count groups 1280. One free physical block 1120 is prepared for each erasure count group 1280.
While in the present embodiment the respective ranges of erasure count of the physical block groups B1220-F1260 and the erasure count group 1280 are assumed to be equally 1,000, the present invention is applicable even when this value is changed. The number of physical block groups 1200 is not necessarily limited to 7 (A-G). Two or more free physical blocks 1120 may be allocated to each erasure count group 1280. In this case, if there is a request for writing data having a size of two or more blocks from the host computer 1010, data for the total capacity of a plurality of free prepared physical blocks 1120 can be written consecutively into those free prepared blocks even when other physical blocks are not erased.
Like the physical blocks 1110, the logical blocks 1100 are classified according to write count into logical block groups.
FIG. 4 shows the concept of a logical block group 1300 (logical blocks 1310-1370). The axis of abscissas shows a write count of a logical block 1100 while the axis of ordinates shows the number of logical blocks 1100 belonging to each group. The logical blocks 1100 are grouped according to reference write count "n"which is a multiple of 1,000 and which satisfies a condition "n≦average write count<n+1,000" (in FIG. 4, n which satisfies the above condition is 3,000) into a logical block group A1310 of logical blocks 1100 having write counts of 0 to n-2,001, logical block group B1320 of logical blocks 1100 having write counts of n-2,000 to n-1,001, logical block group C1330 of logical blocks 1100 having write counts of n-1,000 to n-1, logical block group D1340 of logical blocks 1100 having write counts of n to n+999, logical block group E1350 of logical blocks 1100 having write counts of n+1,000 to n+1,999, logical block group F1360 of logical blocks 1100 having write counts of n+2,000 to n+2,999, and logical block group G1370 of logical blocks 1100 having write counts of n+3,000 or more. The average write count is included in the logical block group D1340 in dependence on the definition of n.
While in the present embodiment the respective ranges of write count of the logical block groups B1320-F1260 are equally handled as 1000, this value may be changed in order to apply the present invention. In addition, the number of groups may be changed to apply the present invention.
FIG. 5 shows a logical block table 1400 which places the logical blocks 1100 and physical blocks 1110 in a corresponding relationship. The logical block table 1400 has an entry for each logical block 1100. Each logical block table entry 1410 stores data on a corresponding physical block number 1420 and a write count into a logical block corresponding to the physical block.
FIG. 6 shows a physical block table 1500, which has a physical block table entry 1510 for each physical block 1110. The physical block table entry 1510 has a free flag 1520 indicative of whether a physical block concerned is free, an erasure count 1530 of that physical block, a forward pointer 1540 and a backward pointer 1550 which are the entity of a group queue 1800 to be described later in more detail. For convenience of simplification in the present embodiment, the forward and backward pointers 1540 and 1550 store not the value (address) of the pointer to the physical block 1110, but the physical block number. Of course, it may store the value of the pointer to the physical block 1110.
The physical blocks 1110 corresponding to the logical blocks 1100 are classified into the physical block groups 1200, as described above, and managed as queues classified for the respective logical block groups 1300 of the logical blocks 1100 corresponding to the physical blocks 1110. Those queues are referred to as group queues 1800. Free physical blocks 1120 are prepared one for each of the erasure count groups 1280 and managed by the free physical block table 1600.
FIG. 7 shows a free physical block table 1600, group queues 1800 and a group table 1620 which manages the group queues 1800. By provision of the group table 1620, a physical block from which data is to be copied, which is hereinafter abbreviated as a "data-copy-from physical block" (and a physical block in which data is to be written, which is hereinafter abbreviated as a "data-write-in physical block"), especially in the exchange write processes, is retrieved rapidly, as will be described later.
The free physical block table 1600 has entries 1610 for the number of erasure count groups 1280 with each entry 1610 storing physical block numbers of the free physical blocks 1120 belonging to the erasure count group 1280. (As described above, in the present embodiment, all the erasure count groups 1280 each have at least one free physical block at all times. The entries 1610 of the free physical block table 1600 corresponding to physical block groups A and G are allocated many free physical blocks which do not belong to the other physical groups.) The entity of the group queue 1800 includes a forward pointer 1540 and a backward pointer 1550 stored in the physical block table 1500 and composing a bilateral connection list. The group table 1620 has an entry for each of the physical block groups 1200. Each entry has a queue entry 1710 of the physical blocks 1110 corresponding to the logical blocks 1100 belonging to the logical block group A1310, a queue entry 1720 of the physical blocks 1110 corresponding to the logical blocks 1100 belonging to the logical block group B1320, a queue entry 1730 of the physical blocks 1110 corresponding to the logical blocks 1100 belonging to the logical block group C1330, a queue entry 1740 of the physical blocks 1110 corresponding to the logical blocks 1100 belonging to the logical block group D1340, a queue entry 1750 of the physical blocks 1110 corresponding to the logical blocks 1100 belonging to the logical block group E1350, a queue entry 1760 of the physical blocks 1110 corresponding to the logical blocks 1100 belonging to the logical block group F1360, and a queue entry 1770 of the physical blocks 1110 corresponding to the logical blocks 1100 belonging to the logical block group G1370. The respective queue entries 1710-1770 store the corresponding physical block numbers of the head positions of the queues. The backward pointers 1550 of the end ones of the respective group queues 1800 store corresponding particular values indicative of the end queues. (For convenience of representation in the drawings, reference numerals 1720-1760 are not shown.)
While the table is stored in the RAM 1030 when the memory system 1000 is used, those data in the RAM 1030 are erased when the power supply is turned off. Thus, as shown in FIG. 26, when the memory system is turned off, the data in the table is stored in the table storage area 1062 of the flash memory 1060 so as not to disappear whereas when the power supply is turned on, the data in the flash memory 1060 is written into the RAM 1030.
The read process of the memory system 1000 of the present invention will be described next with reference to FIG. 8. First, in step 1900 the CPU 1050 determines a physical block 1110 from which data is read, which is hereinafter abbreviated as a "data-read-from physical block", corresponding to a logical block 1100 which has received a read request, on the basis of an entry corresponding to the logical block table 1400. In step 1910 the CPU 1050 then writes data in that data-read physical block 1110 into the RAM 1030. Finally, in step 1920 the host interface 1020 transfers the data written into the RAM 1030 to the host computer 1010.
Since the write process is rather complicated, first, the concept of the write process will be described with reference to FIGS. 9 and 10.
Since the flash memory 1060 is limited in erasure count and takes a millisecond-order erasure time or more, disadvantageously, the inventive memory system 1000 performs a write process which is intended to conquer such drawback.
In more detail, in the write process of the present embodiment, any one of two kinds of write processes; that is, a normal and an exchange write process, is performed according to the erasure count of a literal physical block. The "normal write process" is one performed normally, which is intended to conceal the erasure time from the host device and to maintain the balance between the write count of a logical block 1100 and the erasure count of a corresponding physical block 1110 in the same physical block group. In order to maintain the balance between the write count of the logical block 1100 and the erasure count of the physical block 1110, the process shown in FIG. 9A is performed specifically. A free physical block 2010 belonging to the same erasure count group 1280 (=the same physical block group 1200) as the physical block 1110 corresponding originally to the logical block 1100 in which data is to be written is newly allocated and data is written into the free physical block 2010 such that the erasure count of the physical block 1110 corresponding to the logical block 1100 does not change greatly before and after the write process. The advantages of such process will be described later. The newly allocated physical block 2010 is removed from the free physical block table 1600 and recorded newly into the logical block table 1400. This updates the data in the appropriate entry of the physical block table 1500. The data in the physical block (old physical block 2000) corresponding originally to the logical block is erased and recorded as a free physical block in the appropriate entry of the free physical block table 1600. The logical-physical block correspondence and the situation of the block group after completion of the normal write process are shown in FIG. 9B.
It is predicted that the logical block 1100 having a larger write count will have a relatively strong possibility of receiving a write request in the future. Thus, the "normal write process" is performed to maintain the balance between the write count of the logical block 1100 and the erasure count of the physical block 1110, so that all the physical blocks are divided gradually into physical blocks 1110 which have larger erasure counts and those which have smaller erasure counts. By the exchange write process to be described below, the erasure counts of the physical blocks 1110 are required to be rendered uniform.
When data is written into a physical block 1110 which has a larger erasure count than the averaged one (in an example to be described later, when the erasure count of the data-write-in physical block is a multiple, for example, of 1000), the "exchange write process" is performed to conceal the erasure time and to intend the following two processes:
(1) A physical block 1110 having a smaller erasure count is allocated to a logical block 1100 having a stronger possibility of receiving a write request (a larger write count) in the future; and
(2) A physical block 1110 having a larger erasure count is allocated to a logical block 1100 having a weaker possibility of receiving a write request (a smaller write count) in the future.
As shown in FIG. 10A, the exchange write process is performed when a logical block 1100 having a larger write count corresponding to a physical block 1110 (old physical block 2000) having a larger erasure count receives a write request. At this time, a physical block 1110 having a smaller erasure count and corresponding to a logical block 1110 having a smaller write count (hereinafter referred to as a data-copy-from physical block 2020) is detected, and write data is written into a free physical block 1120 as a data-write-in physical block 2010 and belonging to the same erasure count group 1280 as the data-copy-from physical block 2020. The data written in the data-copy-from physical block 2020 is copied to a free physical block 1120 (physical block to which data is to be copied 2030, which is hereinafter abbreviated as a "data-copy-to physical block" 2030) belonging to the same erasure count group 1280 as the old physical block 2000. Finally, the data-copy-from physical block 2020 and the old physical block 2000 are erased to thereby complete the exchange write process. As will be described later, the data in the respective tables is updated simultaneously with those processes. FIG. 10B shows the logical-physical block correspondence and the state of the respective block groups after the exchange write process has ended.
By performing such exchange write process, a logical block 1100 having a smaller eraser count corresponds to a logical block 1100 having a larger write count while a logical block 1100 having a larger erasure count corresponds to a logical block 1100 having a smaller write count. Thus, the exchange write process causes a physical block 1110 having an extremely larger erasure count and a physical block 1110 having an extremely smaller erasure count to disappear to thereby equal the erasure counts of the physical blocks substantially.
The write process will be described more specifically with reference to FIGS. 11-17. FIG. 11 is a main flow chart indicative of the write process.
First, in step 2100 the host interface 1020 stores write data from the host computer 1010 in the RAM 1030. A physical block group structure changing process to be described later is performed (step 2110). A logical block group changing process to be described later is performed (step 2120). The CPU 1050 retrieves the logical block table 1400 to extract a physical block 1110 corresponding to the logical block 1100 in which data is to be written 1100, which is hereinafter abbreviated as "data-write-in logical block" 1100 and handles it as an old physical block 2000 (step 2130). A logical block group moving process to be described later is performed (step 2140). A physical block group moving process to be described later is performed (step 2150). A free physical block 1120 belonging to the same erasure count group 1280 as the old physical block 2000 is handled as a data-write-in physical block 2010 (step 2160). In step 2170 the CPU 1050 checks the erasure count 1530 of the physical block table 1500 to determine whether the data-write-in physical block 200 is contained in the physical block group F1260 or G1270 or whether the erasure count of the data-write-in physical block 2010 is larger. If not, in step 2200 the normal write process to be described later is performed. If so, in step 2180 the CPU 1050 determines whether the erasure count of the data-write-in physical block 2010 is a multiple of 1000. If so, in step 2190 the exchange write process to be described later is performed. If not in step 2180, the normal write process is performed in step 2200.
While in step 2180 the value of 1000 is used in the present embodiment, the present invention is not limited to this particular value.
A physical block group structure changing process 2110 will be described next. In the present embodiment, the physical block group 1200 is defined such that the average erasure count of the physical blocks 1110 belongs initially to the physical block group D1240. Thus, when the average erasure count increases and the physical blocks 1110 belong to the physical block group E1250, the structure of the physical block group 1200 is required to be changed such that the physical blocks 1110 belonging to the physical block group E1250 are included in the physical block group D1240 at that time. Similarly, the physical block groups A1210 and B1220 are required to be included in the physical block group A, the physical block group C1230 is required to be moved into the physical block group B1220, the physical block groups D1240 is required to be moved into the physical block group C1230, and the physical block group F1260 is required to be moved into the physical block group E1250. The physical block group G1270 is divided into the physical block groups F1260 and G1270 according to erasure count.
FIG. 12 is a flow chart indicative of such physical block group structure changing process 2110, which is performed as a part of the write process (in step 2110 of FIG. 11). First, in step 2300 the total erasure count is incremented by one and the average erasure count is calculated. In step 2310 the CPU 1050 determines whether the average erasure count (FIG. 3) has exceeded the range of the physical block group D1240 (having the average erasure count). If not, control exits the process of FIG. 12. That is, if the average erasure count is on the boundary of the current physical block group, the structure of the physical block group is changed. If the average erasure count is beyond the range of the physical block group D1240, in step 2320 the group table 1620 is changed and the group queue 1800 is reconnected such that all the physical blocks 1110 belonging to the physical block group B1220 belong to the physical block group A1210. At this time, on the basis of the write count of the logical block 1100 corresponding to the physical block 1110, the group queues 1800 of the logical block group 1300 corresponding to the logical block 1100 and the group queue of the free physical block 1120 are reconnected. Similarly, the respective group queues 1800 are reconnected such that the physical blocks 1110 belonging to the physical block group C1230 belong to the physical block group B1220, that the physical blocks 1110 belonging to the physical block group D1240 belong to the physical block group C1230, that the physical blocks 1110 belonging to the physical block group E1250 belong to the physical block group D1240, and that the physical blocks 1110 belonging to the physical block group F1260 belong to the physical block group E1250 (step 2330). For the physical block group G1270, the group queues 1800 are reconnected such that the physical blocks 1110 having an erasure count of m+2,000 to m+2,999 belong to the physical block group F1260 and that the physical blocks 1110 having an erasure count of m+3,000 or more belong to the physical block group G1270, where m is a new reference erasure count which satisfies the condition "m<average erasure count<m+1,000" and which is a multiple of 1,000 (step 2340). The physical blocks of the physical block group G are grouped into two physical block groups F and G according to erasure count.
A logical block structure changing process 2120 will be described next. In the present embodiment, the average write count of the logical blocks 1100 is defined so as to belong necessarily to the logical block group D1340. Thus, when the average write count of the logical blocks increases and they belong to the logical block group E1350, the structure of the logical block group 1300 is required to be changed such that the logical block 1100 which belonged to the logical block group E1350 at the time is included in the logical block group D1340. Similarly, the logical block groups A1310 and B1320 are required to be moved into the logical block group A1310, the logical block group C1330 is required to be moved into the logical block group B1320, the logical block group D1340 is required to be moved into the logical block group C1330, and the logical block group F1360 is required to be moved into the logical block group E1350. The logical block group G1370 is divided into the logical block groups F1360 and G1370 according to write count.
FIG. 13 is a flow chart indicative of such logical block group structure changing process 2120, which is performed as a part of the write process (in step 2110 of FIG. 11). First in step 2400 the total write count is incremented by one and the average write count is calculated. In step 2410 the CPU determines whether the average write count has exceeded the range of the logical block group D1340 (having the average write count). If not, control exits the process of FIG. 13. That is, if the average write count is on the boundary of the current logical block group, the structure of the logical block group is changed. If the average write count is beyond the range of the logical block group D1340, in step 2420 the group table 1620 is changed and the group queue 1800 is reconnected such that all the logical blocks 1100 belonging to the logical block group B1320 belong to the logical block group A1310. At this time, on the basis of the erasure counts of the physical blocks 1110 corresponding to the logical blocks 1100, the group queues 1800 of the physical block group 1200 corresponding to the logical blocks 1100 are reconnected. Similarly, the respective group queues 1800 are reconnected such that the logical blocks 1110 belonging to the logical block group C1330 belong to the logical block group B1320, that the logical blocks 1100 belonging to the logical block group D1340 belongs to the logical block group C1330, that the logical blocks 1100 belonging to the logical block group E1350 belong to the physical block group D1340, and that the logical blocks 1100 belonging to the logical block group F1360 belongs to the logical block group E1350 (step 2430).
For the logical block group G1370, the group queues 1800 are reconnected such that the logical block 1110 having a write count of n+2,000 to n+2,999 belongs to the logical block group F and that the logical blocks 1100 having a write count of n+3,000 or more belong to the logical block group G. where n is a new reference write count which satisfies the condition "n≦average write count<n+1,000" and which is a multiple of 1,000 (step 2440). That is, the logical blocks of the logical block group G are divided into two new logical block groups F and G according to write count.
A logical block group moving process 2140 will be described next with reference to FIG. 14, which is performed as a part of the write process (step 2140 of FIG. 11).
First, in step 2500 the write count of the data-write-in logical block 1000 is incremented by one. It is then determined in step 2510 whether the write count of the data-write-in logical block 1100 has exceeded the range of the logical block group 1300 to which the write count of the data-write-in logical block 1100 has belonged so far and the movement of that logical block 1100 to another logical block group 1300 is required. If not, control ends. If so in step 2520, the old physical block 2000 corresponding to the logical block 1100 which has received the write request is removed from the group queue 1800. In step 2530 the old physical block 2000 is connected to the group queue 1800 of a destination logical block group 1300 of the same physical block group 1200.
A physical block group moving process 2150 will be described with reference to FIG. 15, which is performed as a part of the write process (step 2150 of FIG. 11). First, in step 2600 the erasure count of the old physical block 2000 corresponding to the data-write-in logical block 1100 is incremented by one. It is then determined in step 2610 whether the erasure count of the old physical block 2000 has exceeded the range of the physical block group 1200 to which the old physical block 2000 has belonged so far and the movement of the old physical block 2000 to another physical block group 1200 is required. If not, control ends. If so in step 2620, the old physical block 2000 is removed from the group queue 1800. In step 2630 the old physical block 2000 is connected to the group queue 1800 of a destination physical block group 1200 in the same logical block group 1300.
FIG. 16 is a flow chart indicative of a normal write process 2200, which corresponds to the step 2200 of FIG. 11.
First, in step 2700 the write data in the RAM 1030 is written into a data-write-in physical block 2010. Next, the data-write-in physical block 2010 is removed from the group queue 1800 (step 2710). The entry of the erasure count group 1280, to which the data-write-in physical block 2010 belongs, in the free physical block table 1600 is cleared (step 2720). The old physical block 2000 is then removed from the group queue 1800 (step 2730). At this time, the end of the command is reported to the host computer 1010 (step 2740). The subsequent process is performed in the background, i.e., in the memory system 1000 irrespective of the host computer 1010. The old physical block 2000 is then erased (step 2750). The number of the old physical block 2000 is set in the entry of the free physical block table 1600 cleared in step 2720 (step 2760).
FIG. 17 is a flow chart indicative of an exchange write process 2190, which corresponds to the step 2190 of FIG. 11.
In step 2810 a physical block 1110 having a smaller erasure count corresponding to a logical block 1100 having a smaller write count is retrieved on the basis of the group table 1620 (FIG. 7) and is handled as a data-copy-from physical block 2020. A specified method of extracting the data-copy-from physical block 2020 is as follows:
(1) The group queues 1800 of the logical block groups A, B, C and D are sequentially retrieved in this order. And each queues are contained in the group table entry of the physical block group A, and the first extracted physical block 1110 and the corresponding logical block 1100 are selected. Unless there is no such physical block, the following process (2) is performed;
(2) The group queues 1800 of the logical block groups A, B, C and D are sequentially retrieved in this order. And each queues are contained in the group table entry of the physical block group B, and the first extracted physical block 1110 and the corresponding logical block 1100 are selected. Unless there is no such physical block, the following process (3) is performed;
(3) The group queues 1800 of the logical block groups A, B, C and D are sequentially retrieved in this order. And each queues are contained in the group table entry of the physical block group C, and the first extracted physical block 1110 and the corresponding logical block 1100 are selected. Unless there is no such physical block, the following process (4) is performed; and
(4) The group queues 1800 of the logical block groups A, B, C and D are sequentially retrieved in this order. And each queues are contained in the group table entry of the physical block group D, and the first extracted physical block 1110 and the corresponding logical block 1100 are selected.
Each of the erasure count of the data-copy-from physical block 2020 and the total erasure count is incremented by one (step 2820).
It is then determined whether the movement of the data-copy-from physical block 2020 is required among the physical block group 1200 (step 2830). If so, the data-copy-from physical block 2020 is removed from the group queue 1800 (step 2840) and is connected to the group queue 1800 of a destination physical block group 1200 included in the same logical block group 1300 (step 2850). If not in step 2830, no processes in those two steps 2840 and 2850 are performed.
Then, in step 2860 the physical block 1110 which is the data-write-in physical block 2010 is handled as a data-copy-to physical block 1110. A free physical block included in the same erasure count group 1280 as the data-copy-from physical block is handled as a new data-write-in physical block 2010 (step 2870). Write data in the RAM is written into the data-write-in physical block 2010 (step 2880). An entry of a free physical block table 1600 corresponding to the erasure count group 1280 to which the data-write-in physical block 2010 belongs is cleared (step 2890). In step 2900 the data-write-in physical block 2010 is connected to a correct group queue 1800, which implies that the data-write-in physical block 2010 is connected to the group queue 1800 which corresponds to the logical block group 1300 which includes the data-write-in logical block, and the physical block group 1200 which includes the data-write in physical block 2010.
The host interface 1020 reports the end of the command to the host computer 1010 (step 2910). The subsequent process is performed in the background, i.e., in the memory system 1000 irrespective of the host computer 1010.
In step 2920 data in the data-copy-from physical block 2020 is written temporarily into the RAM 1030 and thence into the data-copy-to physical block 2030. An entry of a free physical block table 1600 corresponding to the erasure count group 1280 to which the data-copy-to physical block 2030 belongs is cleared (step 2930). In step 2940 the data-copy-to physical block 2030 is connected to a correct group queue 1800, which implies the same matter as mentioned above. The data-copy-from physical block is then erased (step 2950). The physical block number of the data-copy-from physical block 2020 is then set in the entry of the erasure count group 1280 which includes the data-copy-from physical block 2020 in the free physical block table 1600 (step 2960). The old physical block 2000 is then erased (step 2970). The physical block number of the old physical block 2000 is then set in the entry of the erasure count group 1280 which includes the old physical block 2000 in the free physical block table 1600 (step 2980).
While in the present embodiment the write count of the logical block 1100 has been used as management information, the write frequency (time differentiation of the write count) of the logical block 1100 may be used instead. The write frequency is the count of a counter incremented by one each time a write process is performed like the total write count and is cleared to 0 periodically, for example once every three days, so that the write frequency expresses the latest write count or frequency.
In the present embodiment, one free physical block 1120 is prepared for each erasure count group. Thus, when data having a size corresponding to two or more logical blocks 1100 is required to be written and corresponds to the physical block 1110 belonging to the same physical block group 1200, no erasure time can be concealed in the write process of data into the second and subsequent physical blocks 1110. However, if two or more free physical blocks 1120 are prepared for each erasure count group, and if (1) the data write processes are performed collectively, (2) the completion of the write processes is reported to the host computer 1010 and (3) required data erasure processes are performed collectively, the erasure time can be concealed from the host computer 1010 even in the above case, i.e., where the data having a size corresponding to two or more logical blocks 1100 is required to be written and corresponds to the physical block 1110 belonging to the same physical block group 1200.
A memory system 1001 having a data compressing function and using a flash memory will be described as a second embodiment of the present invention below.
FIG. 18 shows the memory system 1001 of the second embodiment, which has a structure which includes a combination of the memory system 1000 of FIG. 1 and a compression and expansion unit 1070.
In the present embodiment, one logical block 1000 corresponds to one--eight physical blocks 1110 in dependence on the degree of data compression. Each logical block 1100 has a size corresponding to eight physical blocks 1110, so that a maximum of eight physical blocks 1110 can be used to store data in the logical block 1100 which can not be compressed at all. In the present embodiment, a logical space which is twice as large as the actual physical space is accessible by the host computer 1010 in consideration of data compression. That is, the whole size of the logical blocks 1100 is twice as that of the physical blocks 1110. Since the number of physical blocks 1110 corresponding to the logical block 1100 varies between one and eight in dependence on the compression rate, a free physical block 1120 is not prepared for each erasure count group 1280 as is in the first embodiment and all physical blocks 1110 which have no effective data stored therein are managed as free physical blocks 1120. In this case, no physical block 1110 is caused to correspond to a logical block 1100 in which no data is written even once.
Only the points of the first embodiment different from those of the second embodiment due to introduction of the compression function will be described next.
FIG. 19 shows a logical block table 1401 and its entry 1411 in the second embodiment. The logical block table entry 1411 has information on a logical block write count 1430, physical block count 1450 corresponding to the logical block 1100, and eight corresponding physical block numbers 1421-1428.
FIG. 20 shows a group table 1621, its entries 1701 and group queues 1800 in the second embodiment. The group table 1621 has entries 1631-1637 of physical block groups A-G each depending on an erasure count, with each entry 1701 including queue entries 1710-1770 for the respective logical block groups in dependence on the write count. In the second embodiment, the free physical block 1120 is also managed by queue. Thus, the group table entry 1701 further has a queue entry 1780 of the free physical block 1120.
In the read process, the expansion of the compressed data is required. Thus, after step 1910 of FIG. 8, the read data is expanded and the resulting data is transferred to the host computer 1010.
The write process requires the compression of the write data. The number of physical blocks 1110 required for storage can change in dependence on the compression rate of the write data, so that allocation of a free data-write-in physical block 1120 becomes complicated.
FIG. 21 is a main flow chart indicative of the write process in the second embodiment, which is different in many points from the first embodiment, so that the whole write process of the second embodiment will be described next.
First, in step 4100 a host interface 1020 stores write data from the host computer 1010 into the RAM 1030. The compression/expansion unit 1070 compresses write data (step 4110). The CPU 1050 calculates the number of free physical blocks 1120 required for storage of the compressed data (step 4120). A physical block group structure changing process to be described later is performed (step 4130). The logical block group structure changing process (FIG. 13) is then performed (step 2120). The CPU 1050 checks the logical block table 1401 to locate a plurality of physical blocks 1110 corresponding to the data-write-in logical block 1100 and handles them as the old physical blocks 2000 (step 4150). The logical block group moving process of FIG. 14 is then performed (step 2140). The physical block group moving process of FIG. 15 is then performed (step 2150). A data-write-in physical block determining process which will be described later is then performed (step 4180). The CPU 1050 selects one of the data-write-in physical blocks 2010 and handles it as a data-write-in physical block 2011 (step 4190).
In step 4200 the CPU 1050 checks the erasure count 1530 of the physical block table 1500 to determine whether the data-write-in physical block 2011 is included in the physical block group F1260 or G1270. If not, in step 4230 the CPU 1050 performs a normal write process to be described later. If so in step 4200, the CPU 1050 further determines in step 4210 whether the erasure count of the data-write-in physical block 2011 is a multiple of 1000. If so, in step 4220 the CPU 1050 performs an exchange write process to be described later. If not in step 4210, the CPU 1050 performs the normal write process in step 4230.
In step 4240 the CPU 1050 determines whether the whole write data has been written into the data-write-in physical block 2010. If not, control passes to step 4190. Finally, the CPU 1050 performs the erasure process to be described later in more detail (step 4250).
The physical block group structure changing process 4130 is different from the physical block group structure changing process 2110 of FIG. 12 in its step 2300. That is, in the second embodiment, the number of physical blocks 1110 required for storage of compressed data is added to the total erasure count, and the average erasure count is then calculated.
The data-write-in physical block determining process 4180 will be described next. In the second embodiment, one - eight data-write-in physical blocks 2010 are required in dependence on the compression rate of the write data. The number of data-write-in physical blocks 2010 can differ from that of old physical blocks 2000. Thus, when physical blocks 1120 required for storage of write data are not larger in number than the old physical blocks 2000, free physical blocks 1120 which have substantially the same write count as the old physical blocks corresponding to data-write-in physical blocks 2010 are required to be allocated to the old physical blocks 2000 in order to determine data-write-in physical blocks 2010 by placing the old physical blocks 2000 and the data-write-in physical blocks 2010 in one-to-corresponding relationship. When the required free physical blocks 1120 are larger in number than the old physical blocks 2000, the write count of the logical block 1100 which has received a write request is required to be checked and a free physical block 1120 depending on the write count is required to be allocated in order to determine the data-write-in physical blocks 2010 which have no corresponding old physical blocks 2000.
The data-write-in physical block determining process 4180 will be described specifically with reference to a flow chart of FIG. 22 below. First, in step 3010 a variable num is set at 0. In step 3020 the variable num is incremented by one. In step 3030 it is determined whether there is a num-th old physical block 2000. If not, control passes to step 3100. If so in step 3030, it is determined in step 3040 whether there are any free physical blocks 1120 in the physical block group 1200 to which the num-th old physical block 2000 belongs. If so, control jumps to step 3080. If not in step 3040, it is determined in step 3050 whether the data-write-in logical block 1100 belongs to a logical block group 1300 having a relatively small write count, which specifically points out any one of the logical block groups A1310-C1330 of FIG. 4. If the write count belongs to one of those groups, in step 3060 a free physical block 1120 is located in the physical block group 1200 having a larger erasure count which is as close as possible to the physical block group 1200 to which the num-th old physical block 2000 belongs. If not in step 3050, a free physical block 1120 is located in a physical block group 1200 having a smaller erasure count which is as close as possible to a physical block group 1200 to which the num-th old physical block 2000 belongs (step 3130). It is determined in step 3070 whether the free physical block has been discovered. If not, control jumps to step 3140. If so in step 3070, the located free physical block 1120 is handled as a num-th data-write-in physical block 2010 in step 3080.
It is then determined in step 3090 whether the num is equal to the number of free physical blocks 1120 required for storage of the write data or whether all the necessary free physical blocks 1120 have been ensured. If so, the data-write-in physical block determining process ends. If not, control returns to step 3020.
It is determined in step 3100 whether the data-write-in logical block 1100 belongs to a logical block group 1300 having relatively small write counts, which specifically points out the logical block groups A1310-C1330. If so, a free physical blocks 1120 is located in order of physical block groups D1240, C1230, B1220 and A1210, and then in order of physical block groups E1250, F1260 and G1270. Control then jumps to step 3070 (step 3110). If not in step 3100, a free physical block 1120 is located in order of physical block groups A1210, B1220, C1230, D1240, E1250, F1260 and G1270. Controls then jumps to step 3070 (step 3120).
In step 3140 any free physical block 1120 present at this time is located in any event, irrespective of the erasure count. If such physical block 1120 is located, it is handled as a num-th data-write-in physical block 2010. It is then determined in step 3150 whether any free physical block 1120 has been located. If so, control jumps to step 3090. If not in step 3150, the message "The write process is impossible" is sent to the host computer 1010 in step 3160 and the write process is terminated abnormally in step 3170.
FIG. 23 is a flow chart indicative of a normal write process 4230 in the second embodiment. First, in step 4700 unwritten compressed write data for one physical block in the RAM 1030 is written into a selected data-write-in physical block 2010, which is then removed from the group queue 1800 (step 4710) and connected to a correct group queue 1800 (step 4720). In step 4730 the end of the command is reported to the host computer 1010.
FIG. 24 is a flow chart indicative of an exchange write process 4220. First, in step 4810 one physical block 1110 having a smaller erasure count corresponding to a logical block 1100 having a smaller write count is located by viewing the group queue 1800 and handled as a data-copy-from physical block 2020. The erasure count of the data-copy-from physical block 2020 and the total erasure count are each incremented by one (step 4820). It is then determined whether the movement of the data-copy-from physical block 2020 is required among the physical block groups 1200 (step 4830). If so, the data-copy-from physical block 2020 is removed from the group queue 1800 (step 4840) and connected to the group queue 1800 of a destination physical block group 1200 and included in the same logical block group 1300 (step 4850). If not in step 4830, the processes in the above two steps 4840 and 4850 are not performed.
In step 4860 the physical block 1110 which is the selected data-write-in physical block 2010 is handled as a data-copy-to physical block 2030. A free physical block included in the same erasure count group 1280 as the data-copy-from physical block 2020 is handled a newly selected data-write-in physical block 2010 (step 4870). Write data in the RAM is written into the data-write-in physical block 2010 (step 4880). The selected data-write-in physical block 2010 is then removed from the group queue 1800 and connected to a correct group queue 1800 (step 4890).
At this time, the host interface 1020 reports the end of the command to the host computer 1010 (step 4900). The subsequent process is performed in the background, i.e., in the memory system 1001 irrespective of the host computer 1010. In step 4910 data in the data-copy-from physical block 2020 is temporarily written into the RAM 1030 and then written into the data-copy-to physical block 2030. In step 4920 the data-copy-to physical block 2030 is removed from the group queue 1800 and connected to a correct group queue 1800.
FIG. 25 is a flow chart indicative of an erasure process 4250. First, in step 3210 it is determined whether there are any old physical blocks 2000. When data is not overwritten, but written initially into a logical block 1100, this logical block 1100 has no corresponding physical block 1110. Thus, there are no old physical blocks 2000. In this case, controls jumps to step 3240. If there are old physical blocks 2000, they are all erased (step 3220). All the old physical blocks 2000 are then removed from the group queue 1800 and connected to a correct group queue (step 3230).
It is then determined in step 3240 whether an exchange write process 4220 has been performed by using a flag set in this process. If not, the erasure process ends. If so in step 3240, all the data-copy-from physical blocks 2020 are erased (step 3250). All the data-copy-from physical blocks 2020 are removed from the group queue 1800 and connected to a correct group queue (step 3260).
According to the present invention, erasure counts are equalized among a plurality of physical blocks to thereby realize a memory system which uses a flash memory and which is long in service life and high in response performance compared to the conventional memory system using flash memory.
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A memory system includes a flash memory having a plurality of individually erasable physical blocks, table section for holding the relationship in correspondence between the logical blocks allocated by the allocation section and the physical blocks first counting and managing section for counting and managing write counts of the respective logical blocks, first classifying section for classifying the logical blocks into a plurality of groups on the basis of the respective write counts of the logical blocks, erasure section for erasing data in a physical block allocated to a logical block to produce a free physical block, second counting and managing section for counting and managing the erasure counts of the respective physical blocks, second classifying section for classifying the physical blocks into a plurality of groups on the basis of the respective erasure counts of the physical blocks, control section for allocating the respective logical blocks to the physical blocks; and managing section for managing free physical blocks which are not allocated to any logical blocks.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of US patent application Ser. No. 13/382,809, filed Mar. 1, 2012, which is a 35 U.S.C. §371 National Phase Application of and claims the benefit and priority to PCT/EP2010/059571, filed Jul. 7, 2010, published as WO2011/003952 on Jan. 13, 2001, which claims the benefit of and priority to GB 0911822.5, filed Jul. 8, 2009.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The main purpose of the present invention is to provide crosslaminates of low gauge with an improved feel of substance.
[0004] 2. Description of the Related Art
[0005] A crosslaminate comprising a film (A) which has a waved shape and a film (B) which has a flat shape is known from WO02/102592 Rasmussen, and a crosslaminate comprising two films (A) and (B) which both have waved shape, with the directions of the two sets of waves crossing each other, is known from WO04/054793 Rasmussen. The general technology of crosslaminates, the purposes of the waving (fluting) and methods and apparatus to achieve this structure are explained in these two publications.
SUMMARY OF THE INVENTION
[0006] One purpose of the fluted shape is to obtain improved stiffness in respect of bending, and another purpose is to give the crosslaminate an improved feel of substance. A further purpose is to improve the heat seal properties. It has also been found that the fluted shape improves the tear propagation resistance.
[0007] With the increased request for raw material saving there is an increasing need to reduce the weight per square meter of such fluted crosslaminates and crosslaminates of related structures, while still obtaining good stiffness with respect to bending and a clearly improved feel of substance, compared to the stiffness and feel of flat crosslaminates. These goals are objectives of the present invention, and in a first aspect of the invention are achieved by a suitable encasement of gas (normally atmospheric air) between the laminated films.
[0008] It is known from the above mentioned WO02/102592, claims 17 and 25 , that the flutes can be flattened at intervals and bonded across each ones entire width to form a row of narrow closed elongated pockets. The encased gas (e.g. atmospheric air) helps to provide the laminate with increased feel of substance and increased stiffness in one direction.
[0009] In trials preceding the present inventions the inventors have repeated the fluting/crosslaminating procedure described in the example in WO02/102592, however with a much lower gauge of each of the two films in the crosslaminate, namely 20 g m −2 referring to the non-fluted shape. The result was a very “sloppy” laminate. Then the flutes were flattened and bonded at intervals by means of a simple pair of sealer bars heated to 105° C., so as to encase the air in each of the flutes. This considerably increased the feel of “substance” and the stiffness in one direction.
[0010] However, this encasement of air also proved to cause problems, e.g. attempts to carry out flexographic printing on the crosslaminate gave a poor result. Furthermore, measurements of friction between two sheets of the crosslaminate turned perpendicular to each other (like stacked bags) showed very low values, for the coefficient of friction.
[0011] The basic idea behind a first aspect of the present invention is that the gas (air) should not be encased in a “one dimensional” pocket namely a pocket which comprises only one flute, but should be encased in a “two dimensional” pocket comprising several flutes, in such a way that within each pocket there is a passage for gas from each flute to one or both of the adjacent flutes.
[0012] To try this, the bonding between the waved film (A) and the flat film (B) was not formed as a line bonding as in the known procedure, but was made a spot-bonding, and the encasement of gas was not by transverse welding lines alone, but by a combination of transverse and longitudinal welding lines. In this manner, the gas could freely move from flute to flute within each of the pockets formed by the two systems of welding lines.
[0013] This very considerably improved the printing quality, since the gas was removed from the locations which came under pressure. When the printing pressure was released, the gas returned and reshaped the flute. It was also found that the handle of the product was improved.
[0014] Furthermore it is believed that bags made from such film will show better stacking properties, e.g. when the content consists of coarse grains. This effect will be similar to the mentioned effect of printing.
[0015] In accordance with these remarkable results, the first aspect of the present invention 1 , describes a crosslaminate comprising at least two bonded-together films (A) and (B), each comprising an orientable, crystalline thermoplastic polymer material and each being uniaxially oriented or being biaxially oriented with one direction dominating, the directions in (A) and (B) crossing each other, the bonding being an intermittent bonding which leaves more than 50% of the film area unbonded and which forms pockets to encapsulate gas, whereby the gas within each pocket has a volume which referring to the relaxed state of the laminate and 1 atmosphere ambient pressure is at least double the volume of the polymer material, where a) the gauge of each of the films (A) and (B) is at the highest 30 g m −2 in the form it has in the crosslaminate, b) the bonding consists in a combination of a pattern of rectilinear or curved bonding lines ( 4 ), which are combined to form the gas encapsulating pockets, and within each pocket at least 5 spot bonds ( 3 ), and c) the longest extension of each pocket in any direction is at the highest 50 mm. In accordance with these remarkable results, the first aspect of the present invention also describes a method of manufacturing a crosslaminate comprising at least two bonded-together films (A) and (B), each comprising an orientable, crystalline thermoplastic polymer material in which each is supplied with uniaxial orientation or being biaxially oriented with one direction dominating, and the directions in films (A) and (B) is brought to cross each other, bonding being carried out as an intermittent bonding which leaves more than 50% of the film area unbonded and which forms pockets to encapsulate gas, whereby the gas within each pocket has a volume which referring to the relaxed state of the laminate and 1 atmosphere ambient pressure at least is double the volume of the polymer material, where a) the gauges of starting materials and conditions of orientation are such that the gauge of each of the films (A) and (B) is at the highest 30 g m −2 in the form it has in the crosslaminate, b) the bonding is carried out as a combination of a patterns of rectilinear or curved bonding lines ( 4 ), which are combined to form the gas encapsulating pockets, and within each pocket at least 5 spot bonds ( 3 ) and such that c) the longest extension of each pocket in any direction is at the highest 50 mm.
[0016] In this connection the volume of the gas in a certain pocket can be determined by cutting out the pocket and measuring its buoyancy in water optionally containing a low level of surfactant to minimize air bubble attachment at the product surface, while the corresponding volume of the polymer material is determined by the weight of the pocket divided by the density of the polymer material.
[0017] In this structure one film (A) and optionally also the second film (B) may have a fluted shape, where the film (A) has a fluted shape, the pitch of the flutes ( 103 ) measured from middle to middle of adjacent flutes on the same side of film (A) is at the highest 3 mm, the bonding spots ( 2 ) are arranged on the crests of the flutes of (A) on the side facing (B), the distance ( 104 ) from middle to middle of adjacent spots ( 2 ) measured along the flutes, is at the highest 3 mm, and each encapsulated pocket comprises at least 2 flutes, where the film (B) also has a fluted shape the pitch of said flutes ( 105 ) measured from middle to middle of adjacent flutes on the same side of film (B) is at the highest 3 mm, and the bonding spots ( 2 ) are arranged on the crests of the flutes on the side of (B) facing (A) and wherein the film (A) is supplied with cup shaped or trough shaped bosses, and the spot-bonding is localized to crown portions or base portions of the bosses. However, there is the alternative possibility that one film (A) is supplied with cup shaped or trough shaped bosses, whereby the spot-bonding is localised to crown portions or base portions of all or some of the bosses, as further explained below. A third film (C), supplied with similar bosses, may be included in such laminate. These possibilities a crosslaminate wherein the film (A) is supplied with cup shaped or trough shaped bosses, and the spot-bonding is localized to crown portions or base portions of the bosses, wherein the film (B) is an unembossed film, in form of a coat produced by extrusion coating so as to establish the orientation of (B) as a longitudinal melt orientation, and to establish the spot-bonding simultaneous with the coating when the molten (B) touches the crown portions or based portions of bosses on (A), the lamination pressure being adjusted such that more than 50% of the film area is left unbonded, whereas the dominating direction of orientation of (A) forms an angle to the longitudinal direction, further comprises a third film (C) on the side of (A) which is opposite to (B) which film (C) is uniaxially oriented or is biaxially oriented with one direction dominating, and which also is supplied with cup shaped or trough shaped bosses, and the film (B) is an unembossed film in form of a tie layer produced by extrusion lamination so as to establish the orientation of (B) as a longitudinal melt orientation, and to establish the spot-bonding when the molten (B) touches the crown portions or base portions of bosses on (A) and the crown portions or base portions of bosses on (C), the laminate pressure being adjusted such that more than 50% of the area of each of the films (A) and (C) is left unbonded, whereas the dominating directions of (A) and (C) from an angle to the longitudinal direction, wherein the dominating direction of (C) crosses the dominating direction of (A) and a crosslaminate comprising at least two bonded-together films (A) and (B), each comprising an orientable, crystalline thermoplastic polymer material and each being uniaxially oriented or being biaxially oriented with one direction dominating, said directions in (A) and (B) crossing each other, the bonding comprising a spot bonding, where a) the gauge of each of the films (A) and (B) is at the highest 30 g m −2 in the form it has in the crosslaminate, b) film (A) is supplied with cup shaped or trough shaped bosses, the spot-bonding being localized to crown portions or to base portions of such bosses on one side of film (A), c) film (B) is an unembossed film, d) the bonding between the film (A) and the film (B) is a spot bonding established on crown portions or base portions of bosses on (A) while at least 25% and preferably at least 50% is kept free of bonding, and e) the dominating direction of orientation in (A) forms an angle higher than zero and preferably higher than 10° to the longitudinal direction. By “cup shaped or trough shaped bosses” is meant spots of the film in which both surfaces protrude to the same side. The spots can be elongated in on direction. Examples of such embossment are given or referred to in WO9112125, U.S. Pat. No. 5,205,650 FIGS. 1 , 2 a , 2 b and 3 , and the microphotos shown in WO2009090208.
[0018] The word “bosses” is also occasionally used to indicate spot or line which is essentially thicker than the adjacent film material, and thereby protruding to both sides of the film but this is not the meaning in the present specification.
[0019] The crosslaminate consisting of an embossed film and an unembossed film can be characterised as a “cellular crosslaminate”. In the description above it is mentioned than film (B) can be bonded either to crown portions or to base portions of bosses on (A). The above mentioned Figures in U.S. Pat. No. 5,205,650 show a clear distinction between the bases of bosses on one side and crowns on the other side, and it is easy to image film (B) laminated to one or the other side of this embossed film. (These Figures show an embossment confined to a limited part of the film, but the description of the patent teaches that the embossment may comprise the entire film). Contrary to these Figures, the microphotos in WO2009090208 show a waved type of embossment with crowns on both sides of the film and no base portions of the bosses, and it is easy to imagine film (B) laminated to crown portions on one or the other side of this embossed film.
[0020] The film (B) which is laminated to the embossed film (A) is a flat film prior to the lamination, but due to the laminate forces and subsequent tendency to shrinkage, film (B) may in the final laminate have lost its flatness.
[0021] It is noted that the low weight crosslaminate structure, comprising the film (A) with cup shaped or trough shaped bosses, and the unembossed film (B), which has been formed by extrusion coating, and thereby has just “kissed” film (A) and formed spot bonds, in itself is considered inventive independent of the formation of pockets to encapsulate the gas. This second aspect of the invention is a crosslaminate comprising at least two bonded-together films (A) and (B), each comprising an orientable, crystalline thermoplastic polymer material and each being uniaxially oriented or being biaxially oriented with one direction dominating, said directions in (A) and (B) crossing each other, the bonding comprising a spot bonding, where a) the gauge of each of the films (A) and (B) is at the highest 30 g m −2 in the form it has in the crosslaminate, b) film (A) is supplied with cup shaped or trough shaped bosses, the spot-bonding being localized to crown portions or to base portions of such bosses on one side of film (A), c) film (B) is an unembossed film, d) the bonding between the film (A) and the film (B) is a spot bonding established on crown portions or base portions of bosses on (A) while at least 25% and preferably at least 50% is kept free of bonding, and e) the dominating direction of orientation in (A) forms an angle higher than zero and preferably higher than 10° to the longitudinal direction. The purpose of this second aspect of the invention is to provide a low weight crosslaminate with improved stiffness, feel of substance and a textile like handle. A method of crosslaminating films comprising the steps: 1) arranging two films (A) and (B), each comprises an orientable, crystalline thermoplastic polymer material and being uniaxially oriented or being biaxially oriented with one direction dominating, in face-to-face relationship with the the orientation directions in (A) and (B) crossing one another; 2) bonding the films to one another by a spot-bonding process to form a crosslaminate, where: a) a gauge of each of the films (A) and (B) is at the highest 30 g m −2 , measured as in the laminate; b) film (A) as used in step 1) has cup shaped or trough shaped bosses; c) the bonding in step 2) is localized to cover crown portions or base portions of the bosses on the side of the film (A) facing film (b); d) film (B) is formed as an unembossed film by extrusion carried out in a manner to establish its orientation as a longitudinal melt orientation and as to establish the spot-bonding in step 2) as the molten material of (B) touches the crown or base portions of bosses on film (A) while keeping at least 25%, preferably at least 50%, of the facing area of the films without any bonding, and wherein the said orientation of film (A) is at an angle to the longitudinal direction.
[0022] To increase the tear propagation resistance and the peel strength of the laminate, the films may further be bonded together by curved or recti linear bonds, which for these purposes need not form gastight pockets.
[0023] Most processes to produce cup or trough shaped bosses will make the film in these bosses thinner than the surrounding film. However, in the structure described below, most of the film portions in the bosses are thicker than the adjacent film portions, and this is an advantage for the stability of the structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The invention is illustrated in the accompanying sketches.
[0025] FIG. 1 shows a crosslaminate of two oriented films (A) and (B), which both are fluted. In each film the main direction of orientation coincides with the direction in which its flutes extend.
[0026] FIG. 2 shows a crosslaminate of an embossed film (A), which is oriented under acute angles to the machine direction, and a generally flat film (B) formed by extrusion coating, by which it has received melt orientation in the machine direction. During the coating the two films have “kissed” each other to form spot-bonding, such that more than 50% of the film area is left unbonded.
[0027] FIG. 3 shows this special carrying out of extrusion coating, referred to as the second aspect of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0028] As already stated, a main objective of both aspects of the invention is to reduce the square meter weight of crosslaminates while still obtaining good stiffness with respect to bonding and especially a feel of substance. Accordingly, a crosslaminate comprising at least two bonded-together films (A) and (B), each comprising an orientable, crystalline thermoplastic polymer material and each being uniaxially oriented or being biaxially oriented with one direction dominating, the directions in (A) and (B) crossing each other, the bonding being an intermittent bonding which leaves more than 50% of the film area unbonded and which forms pockets to encapsulate gas, whereby the gas within each pocket has a volume which referring to the relaxed state of the laminate and 1 atmosphere ambient pressure is at least double the volume of the polymer material, where a) the gauge of each of the films (A) and (B) is at the highest 30 g m −2 in the form it has in the crosslaminate, b) the bonding consists in a combination of a pattern of rectilinear or curved bonding lines ( 4 ), which are combined to form the gas encapsulating pockets, and within each pocket at least 5 spot bonds ( 3 ), and c) the longest extension of each pocket in any direction is at the highest 50 mm. set the limit of 30 g m −2 for the gauge of each of the films (A) and (B) in the form which the film has in the crosslaminate and a crosslaminate comprising at least two bonded-together films (A) and (B), each comprising an orientable, crystalline thermoplastic polymer material and each being uniaxially oriented or being biaxially oriented with one direction dominating, said directions in (A) and (B) crossing each other, the bonding comprising a spot bonding, where a) the gauge of each of the films (A) and (B) is at the highest 30 g m −2 in the form it has in the crosslaminate, b) film (A) is supplied with cup shaped or trough shaped bosses, the spot-bonding being localized to crown portions or to base portions of such bosses on one side of film (A), c) film (B) is an unembossed film, d) the bonding between the film (A) and the film (B) is a spot bonding established on crown portions or base portions of bosses on (A) while at least 25% and preferably at least 50% is kept free of bonding, and e) the dominating direction of orientation in (A) forms an angle higher than zero and preferably higher than 10° to the longitudinal direction. However, this gauge can with advantage be at the highest 20 g m −2 or even no more than 15 g m −2 .
[0029] Process steps for manufacture of the crosslaminate which exhibited fluted shape, as these crosslaminates wherein the film (A) has a fluted shape, the pitch of the flutes ( 103 ) measured from middle to middle of adjacent flutes on the same side of film (A) is at the highest 3 mm, the bonding spots ( 2 ) are arranged on the crests of the flutes of (A) on the side facing (B), the distance ( 104 ) from middle to middle of adjacent spots ( 2 ) measured along the flutes, is at the highest 3 mm, and each encapsulated pocket comprises at least 2 flutes and wherein the film (B) also has a fluted shape the pitch of said flutes ( 105 ) measured from middle to middle of adjacent flutes on the same side of film (B) is at the highest 3 mm, and the bonding spots ( 2 ) are arranged on the crests of the flutes on the side of (B) facing (A), appear from the above mentioned publications WO02/102592 Rasmussen and WO04/54793 Rasmussen, but in the first aspect of the present invention, to these well known steps there must be added the step of further sealing the films together in a pattern of rectilinear or curved lines ( 1 ), which are combined to form the gas encapsulating pockets, each surrounding at least 5 of the spot bonds, which were formed by the known steps. The longest extension of each pocket in any direction is at the highest 50 mm, preferably at the highest 30 mm and preferably at least 6 mm.
[0030] An embossed film, which for the reason stated above is particularly suitable for manufacture of the product described herein, is disclosed in WO2009090208. This was not published when the priority forming patent application for the present application was filed. Such film is formed of thermoplastic polymer material and comprises an array of parallel band-shaped, linearly extending regions (a) and distinct therefrom linearly extending webs (b) which integrally connect said regions. Each web (b) is at each location of its linear extension thinner than the adjacent portions of regions (a).
[0031] In this film both (a) and (b) are oriented having at each location a dominating direction of orientation. The film is characterized in that the dominating direction of orientation in the regions (a) forms angles (v) higher than zero but no higher than 80° with the direction in which (a) extends, and the webs (b) comprise arrays of linear furrows (c) which are necking-down zones, said furrows forming angles (u) higher than (v) to the directions in which (a) extends. The film for use in the present invention is further characterised in that the regions are waved, each wave extending over the width of such region and the webs being shorter than the adjacent parts of the regions (a) so as to force (a) to wave. It is this waving which forms the cup or trough shaped bosses.
[0032] The method of producing such film starts with a film having a predominant direction of orientation. The film is stretched by means of a pair of mutually intermeshing first grooved rollers in a direction which is different, but at the highest 80° different, from the predominant original direction of orientation in the film. The method is characterized in that at least one of the grooved rollers in the pair has crests with edges which are sufficiently sharp to form a distinct division between parallel, linearly extending webs (b) of film material, which have been coldstretched between the crests of the two first grooved rollers and intervening linearly extending band-shapes regions (a), which have laid on the sharp edged crests and have not been stretched or have been stretched to a smaller extend between the said grooved rollers. The contraction which produces the waving of (a) and thereby the bosses, arises inherently if not counteracted.
[0033] In the first aspect of the invention, the pattern bonding lines to encase air consists in its simplest form, two arrays each of parallel straight lines, which arrays crisscross each other. This can be done by means of two pairs of sealing rollers, one pair working in succession to the other, and each pair consisting of a hot steel roller working against a hot, silicone rubber coated roller. One of the steel rollers may be supplied with a pattern of circular crests, e.g. 0.5 mm wide, and the other with axial cogs, e.g. also 0.5 mm wide. Alternatively they may both be supplied with a pattern of helical crests one right turned and the other left turned.
[0034] In a more advanced form this pattern is a honeycomb pattern. This provides better stiffness, but requires more expensive sealing rollers. One roller can be a hot patterned steel roller, working against a hot silicone rubber coated roller.
[0035] These two patterns are only examples of the shapes of the pockets. It is noted that the pattern of bonding lines ( 4 ) which form the pocket for encapsulation of air, additionally has the function that it increases the tear propagation resistance and the peel strength of the laminate.
[0036] During the sealing process to form pockets and encapsulate gas (normally air) the ambient pressure may be kept somewhat higher than the normal atmospheric pressure to achieve a suitable internal tension in the final laminate.
[0037] Each bonding between the films (A), (B) and optionally (C) is preferably established through one or more coextruded lamination layers.
[0038] Most conveniently, more than 50% of each film (A) and (B) consists of HDPE, LLDPE, crystalline PP or blends or copolymers based on polyethylene or polypropylene.
[0039] While the first and second aspect of the present invention primarily have been conceived with a view to water impermeable packaging film, they can also be applied to breathable film, e.g. for sanitary purposes. To this end there may be perforations collected in distinct areas, which areas are interspersed with the air encapsulating pockets.
[0040] In conventional extrusion lamination of two solid films or in extrusion coating, which consists in laminating a directly extruded film to a preformed solid film, the lamination takes place between rollers, and there is applied a relatively high lamination pressure, since otherwise air may be entrapped. However, in the present invention an aim is to entrap a big volume of air, forming a cellular kind of product. To achieve this, a method of laminating a solid film with a molten directly extruded flat film while introducing spaces of gas between the two films, where the lamination pressure is established on one side of the film assembly in the form of a pressurized air film, and on the other side either by a roller surface or by a pressurized air film and an apparatus for extrusion coating a solid film or extrusion laminating two solid films, comprising a flat die for mono- or co-extrusion of a film, and means to bring the solid and the extruded film in face-to-face relationship as an assembly and apply a laminating pressure while at least each surface of the extruded film is in molten or semi molten state, where the means to apply a lamination pressure comprise on one side of the assembly first means to form a first pressurized air film, and on the other side either a roller surface or a second means to form a second pressurized air film, further comprising means to adjust the air pressure exercised on the assembly with subclaims are highly preferable. The formulation of a pressurized air film, normally under use of a microporous wall in a die through which an air flow is pressed, is commonly used as “air lubrication” for many different purposes. In the present invention it is also used as means to set up an easily adjustable and low lamination pressure which at least on one side is contactless, and which enhances the entrapment of air. In this connection it is advantageous but not in all cases necessary that the solid film has been embossed before the lamination.
[0041] A pressurized air film is normally, as explained above, produced by pressing the air through a die wall consisting of microporous material. This is normally formed by sintering. Alternatively the die wall may be supplied with a great multitude of fine holes, e.g. formed by laser treatment. In the present invention the pressurized air film may also be formed by a single slot which traverses the entire width of the film assembly e.g. of 0.1-0.2 mm gap, formed by laser treatement or spark erosion.
[0042] The laminating pressure can be adjusted by adjustment of the spacing of the air film or air films and/or by adjusting the air flows.
[0043] In FIG. 1 lines ( 1 ) show the middle of the longitudinally extending outside crests of the flutes on film (A).
[0044] Similarly, lines ( 2 ) show the middle of the transversely extending outside crests of the flutes on film (B). The dots ( 3 ) show the spot-bonding, which has been established between portions of the two arrays of inside crests. This structure can be made by the procedure described in the example of WO04/54796 Rasmussen, except for the gauge of the films (A) and (B), which must be lower. A perspective view of this structure is shown in FIG. 1 in the same patent specification.
[0045] The new feature is the two arrays of sealing lines ( 4 ), which cross each other. Preferably this sealing is made absolutely tight to encase the air.
[0046] As in the above mentioned example, the bonding between the films is established through coextruded lamination layers.
[0047] In addition to the primary function to encase air, such pattern of sealing lines also serves to improve the tear propagation resistance. For that purpose the sealing needs not be tight, and a “semi-encasing” pattern of rectilinear or curved lines will be satisfactory.
[0048] FIG. 1 shows the wavelength in both films (A) and (B) being 1 mm, the encasement being square formed with edge 10 mm, and the width of the linear seals being 0.5 mm. These measures are generally convenient, but big variations are possible.
[0049] In FIG. 2 the dots ( 3 ) here shown elongated in the machine direction, again illustrate the spot-bonding between the films (A) and (B). The bonding is established between protruding cup shaped or trough shaped bosses by an extrusion coating process, which in principle is shown in FIG. 3 . The embossed film (A), which is molecularly oriented on bias, preferably has a structure disclosed in WO2009090208, briefly explained above in the general description, and may conveniently consist of HDPE. The coating may e.g. consist of LLDPE, LDPE, or a lower melting ethylene copolymer.
[0050] As a matter of simplification of the sketch, FIG. 2 shows the spot-bonding in a very regular pattern, but in actual fact it will be more randomized.
[0051] In FIG. 3 the embossed film (A) with orientation on bias is fed into the coating device as shown by the arrow ( 5 ). It may be taken from a reel or may come directly from the embossment station. The molten film (B) comes from a flat extrusion die ( 6 ) and becomes melt oriented in the machine direction by the draw-down, e.g. from exit slot gap 0.25-0.5 mm to a final thickness between 5-20 micrometer.
[0052] The coating takes place between the two very schematically shown air film forming dies ( 7 ) and ( 8 ). The edge ( 9 ) of die ( 7 ), over which film (A) bends, is rounded, e.g. with radius about 1 cm. The surfaces of the two dies, which face the two films, are produced from microporous material to form pressurized air films, and so is the rounded edge ( 9 ). The pressurized air film formed by die ( 7 ) and blowing on film (A) has ambient temperature, while the pressurized air film formed by die ( 8 ) and blowing towards film (B) has a temperature essentially lower than the exit temperature of the extrusion die ( 7 ) but high enough to cause bonding.
[0053] The coated film is a crosslaminate of the embossed film (A), which is oriented on bias, and the coat, which is melt oriented in the machine direction. It is hauled off by the cooling roller ( 11 ) and the rubber roller ( 12 ). The two rollers are driven by the same circumferential velocity.
[0054] They are very close to each other, but to avoid ruining of the embossed structure they don't press against each other.
[0055] The cross laminate ( 10 ) proceeds to winding (not shown). All the way through the shown process the tension is kept sufficiently low to avoid ruining of the embossment. The devices for this are not shown.
[0056] A suitable bonding, leaving more than 25% of the film area unbonded, is produced by adjustments of 1) the temperature at which film (B) leaves the extrusion die, 2) the positions of dies ( 7 ) and ( 8 ), 3) the temperature of the air film produced by die ( 8 ), and 4) the air velocities of the two air streams.
[0057] The adjustment is such that the two films only “kiss” each other.
[0058] Between roller ( 12 ) and the spooling up there may be sealing rollers to form the lines ( 4 ) shown in FIG. 2 . These may consist of a hot patterned steel roller working against a hot silicone rubber coated roller.
Example 1
[0059] In this and the following two examples the process and apparatus are basically as described in connection with FIG. 3 . The flat extrusion die ( 6 ) is constructed for coextrusion of two components. The gap of the exit orifice is 0.5 mm. In the present example 8-0% of the extruded film consists of HMWHDPE of d=0.95 density 0.95 g/mL and 20% of an ethylene copolymer (“Attane”) melting at about 90 C and of m.f.i.=1.0. The lower melting layer is supplied on the side which will face the solid film. The extrusion temperature is 270 C. The extrusion throughput and the velocity of rollers ( 11 ) and ( 12 ) are adjusted to produce a film thickness calculated of to become 10 micrometers. By the longitudinal draw down in the ratio 50 to 1 the extruded film gets a strong melt orientation.
[0060] The solid film (A) is the single film produced according to example 3 in WO2009/090208. It is deeply embossed with crests of bosses protruding from each side. It is biaxially oriented, differently within different narrow regions, but with a direction near 45° dominating. While it advances towards the die ( 7 ) which supplies a pressurized air film of ambient temperature, all tendencies to wrinkling are removed by means of a driven “banana roller”. The tension in film (A) when it meets the air die ( 7 ) is adjusted to be near zero so as to maintain maximum degree of embossment. It is turned so that its low melting side will face the extruded film (B).
[0061] Throughout the air die ( 8 ), which is heat insulated, hot air is blown. The temperature of the air as it exits this die is adjusted to 100 C. The space between dies ( 7 ) and ( 8 ) is about 5 mm, and the length of the zone in which the two films are under air pressure is above 20 mm. The distance from the exit orifice of the extrusion die ( 6 ) to the two air-dies ( 7 ) and ( 8 ) is also about 20 mm.
[0062] The air for the two dies ( 7 ) and ( 8 ) are taken from the same air reservoir, the pressure of which is adjustable, and the resistance to air flow through the microporous walls in the two dies is practically equal, thus the air filing of both sides have practically the same pressure. The air for die ( 8 ) is heated before it meets the die ( 8 ).
[0063] Between the dies ( 7 ) and ( 8 ) and the first haul off roller ( 17 ) air of ambient temperature is blown onto the laminated film assembly ( 10 ). This is not shown in the drawing.
[0064] By trial and error the pressure in the air reservoir is adjusted to a value which produces the desired degree of lamination, i.e. the desired percentage of bonded areas. This may conveniently be above 25-30%. It is determined by microscopy of samples.
Example 2
[0065] This deviates from example 1 in that the extruded film is a one layer film consisting of the copolymer (Attane) which formed the lamination layer on the extruded film of example 1. In all other respects example 1 is followed.
[0066] In this procedure the extrusion die could have been a monoextrusion die, and this would be a simplification. When using such monoextrusion it is expected that plain LLDPE or HDPE would be applicable in spite of the higher melting points, but this would make the adjustment of cooling conditions more complicated.
Example 3
[0067] In this example the invention is used for extrusion lamination of two solid films with mutually crossing directions of orientation. These two films are the same as the solid film (B) used in examples 1 and 2. As in example 2 the extruded film (B) is the copolymer of (Attane) having melting point around 90° C., and its thickness in the laminate is about 10 micrometers.
[0068] The extruded film (B) is applied between the two solid films, thus the line shown in FIG. 3 is supplemented by apparatus for feeding the additional solid film over the air die ( 8 ), and the latter has a rounded edge like edge ( 9 ) on die ( 7 ).
[0069] In this case air of ambient temperature is used for both pressurized air films formed by dies ( 7 ) and ( 8 ), and there is applied an adjusted flow of cooling air to the extruded film between the exit orifice of the extrusion die ( 6 ) and the two air dies ( 7 ) and ( 8 ).
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Crosslaminates of thermoplastic films have at least one of the films formed as a fluted structure, and two films are laminated to one another in such a manner that pockets are formed which contain gas. The pockets allow passage of gas between at least two adjacent flutes, whereby the product has an improved handle, and bags formed of the laminate have good stacking properties when filled with coarse particulates. The flute pitch is generally no more than 3 mm, while the pocket length is less than 50 mm. The bonding method involves spot bonding between the films, achieved by adhering the films together between crown portions of bosses on one film with molten material on the other film under a low pressure process, for instance achieved by provision of air pressure through adaptation of production apparatus, for instance die portions.
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BACKGROUND OF THE INVENTION
The present invention relates to a formed surface mount resistor and method for making same.
Surface mount resistors have been available for the electronics market for many years. Their construction has comprised a flat rectangular or cylindrically shaped ceramic substrate with a conductive metal plated to the ends of the ceramic to form the electrical termination points. A resistive metal is deposited on the ceramic substrate between the terminations, making electrical contact with each of the terminations to form an electrically continuous path for current flow from one termination to the other.
An improvement in surface mount resistors is shown in U.S. Pat. No. 5,604,477. In this patent a surface mount resistor is formed by joining three strips of material together in edge to edge relation. The upper and lower strips are formed from copper and the center strip is formed from an electrically resistive material. The resistive material is coated with epoxy and the upper and lower strips are coated with tin or solder. The strips may be moved in a continuous path for cutting, calibrating, and separating to form a plurality of electrical resistors.
A primary object of the present invention is the provision of an improved formed surface mount resistor and method for making same.
A further object of the present invention is the provision of a method for making a formed surface mount resistor which utilizes a single ribbon of material for the resistor body and the carrier strip.
A further object of the present invention is the provision of an improved formed surface mount resistor and method for making same which reduces the number of steps and improves the speed of production from that shown in U.S. Pat. No. 5,604,477.
A further object of the present invention is the provision of an improved formed surface mount resistor and method for making same wherein the resulting resistor is efficient in operation and improved in quality.
A further object of the present invention is the provision of a formed surface mount resistor and method for making same which is economical to manufacture, durable in use and efficient in operation.
SUMMARY OF THE INVENTION
The foregoing objects may be achieved by a surface mount resistor comprising an elongated resistive body formed from a single piece of electrically resistive material. The resistive body includes first and second terminal ends and a raised center portion positioned above first and second terminal ends. The raised center portion includes first and second opposite edges and has a plurality of slots extending into the lateral edges so as to create a serpentine current path through the raised center portion from first terminal end to the second terminal end. A dielectric material surrounds and encapsulates the raised center portion. An electrically conductive material coats the first and second terminal ends.
The method for making the surface mount resistor of the present invention comprises taking an elongated ribbon of electrically resistive material having upper and lower ribbon edges. The ribbon is partially separated into a plurality of individual body members, each having opposite side edges and first and second terminal ends with a central portion therebetween. The ribbon includes a carrier portion interconnecting the plurality of body members. A plurality of slots are formed in the opposite side edges of the body members so as to create a serpentine current path from the first terminal end through the central portion to the second terminal end in each of the body members. The cross sectional shapes of the body members are then formed so that the central portion is raised above the first and second terminal ends. The raised central portion is then encapsulated within a dielectric material and the terminal ends of the body members are coated with an electrically conductive material.
In one embodiment of the method the step of forming the cross sectional shape of the body members is performed by forming the ribbon before the separating step is accomplished.
In another embodiment of the method of the present invention the step of forming the cross sectional shape of the body members is performed on the body members after the separating step has been performed.
Various types of forming methods may be used, including roll forming to create the forming of the raised portion or stamping may also be used. Preferably the roll forming method is used when the forming is accomplished before separating the strip into the various body members. Stamping is the preferred method if the forming is accomplished after the body members have been separated.
BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWINGS
FIG. 1 is a perspective view of a resistor made according to the present invention.
FIG. 2 is a schematic flow diagram showing the process for making the present resistor.
FIG. 3 is an enlarged sectional view taken along line 3 — 3 of FIG. 2 .
FIG. 3A is an elevational view taken from the left of FIG. 3 .
FIG. 4 is an enlarged view taken along line 4 — 4 of FIG. 2 .
FIG. 5 is an enlarged view taken along line 5 — 5 of FIG. 2 .
FIG. 6 is an enlarged view taken along line 6 — 6 of FIG. 2 .
FIG. 6A is a sectional view taken along line 6 A— 6 A of FIG. 6 .
FIG. 7 is an enlarged view taken along line 7 — 7 of FIG. 2 .
FIG. 7A is a sectional view taken along line 7 A— 7 A of FIG. 7 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings the numeral 10 generally designates the surface mount resistor of the present invention. Resistor 10 includes a raised center 12 and first and second end terminals 14 , 16 . The bottom surfaces of terminals 14 , 16 form first and second stand offs 18 , 20 which permit the resistor to be mounted on a surface with the raised center 12 spaced above the surface on which the resistor is mounted.
FIG. 2 shows a schematic representation of the method for manufacturing the resistor of the present invention. A reel 22 includes a unitary ribbon 24 wound around it. The ribbon 24 is shown in enlarged detail in FIGS. 3 and 3A. It includes a carrier portion 26 , an upper terminal portion 28 , and a lower terminal portion 30 . Between portions 28 , 30 is a raised center portion 34 . A cut line 32 is represented by a dashed line 32 , and later in the process a longitudinal cut will be made along this line to produce the individual resistors. The ribbon 24 is of unitary construction, and is formed of an electrically resistive material. The preferred material for the resistive material is copper nickel, but other well known resistive materials such as nickel iron, nickel chromium or a copper based alloy may be used.
In one form of the present invention the forming of the raised portion 34 is done by roll forming the resistive strip either before it is wound upon the reel 22 , or after it has been unwound from the reel 22 , but before it has been punched or formed into individual resistors.
In another form of the invention, the resistive material 24 is in a flat unformed state on the reel 22 , and is unwound and formed into individual resistors before the raised portion 34 is formed. In this modified form of the invention the forming of the raised portion 34 may be accomplished by stamping and is preferably accomplished before the individual resistors are separated from the strip.
The numeral 36 in FIG. 2 represents the step of roll forming the resistive strip either before it is placed on reel 22 or immediately thereafter.
The carrier portion 26 of strip 24 is used as an indexing device for carrying the resistors through the entire manufacturing operation.
The next step which is performed on the strip 24 is the punching of transfer holes, represented by block 38 in FIG. 2 . Holes 40 are punched into the carrier strip 26 and are used for indexing the strip through the manufacturing process.
The next step performed on the strip 24 is the step of separating the individual resistor bodies from one another and is represented by the block 42 in FIG. 2 . FIG. 4 illustrates the manner in which this separation process is accomplished. The upper edge of strip 24 is trimmed to provide an upper edge 44 for each of the resistor elements. At the same time a separating slot 46 is formed between each of the resistor bodies. The slots 46 protrude downwardly slightly below the cut line 32 . While various methods may be used for cutting or forming the edges 44 and the slots 46 , the preferred method is to do so by stamping the strip 24 .
FIG. 5 illustrates the result of the adjusting and calibrating step performed on the resistors and represented by the block 60 in FIG. 2 . Side slots 48 , 50 are formed in the edges of the resistor body so as to create a serpentine path represented by arrow 52 for the current to pass from terminal 28 to 30 . During this adjusting process, the slots 48 , 50 are cut preferably by laser and the resistance of the resistance body is monitored and measured until the precise resistance value is achieved.
The next step to be performed on the resistor is the encapsulation of the central portion within a dielectric material, and is represented by block 62 in FIG. 2 . As can be seen in FIGS. 6 and 6A the dielectric material 54 is applied so that it surrounds the entire central portion 34 of the resistor blank.
The purposes of the encapsulating operation include providing protection from various environments to which the resistor may be exposed; adding rigidity to the resistance element which has been weakened by the value adjustment operation; and providing a dielectric insulation to insulate the resistor from other components or metallic surfaces it may contact during its actual operation. The encapsulating material 54 is applied in a manner which only covers the central portion 34 . A liquid high temperature coating material roll coated to both sides of the central portion 34 is the preferred method. The terminal ends 28 , 30 of the resistor blank are left exposed.
Next in the manufacturing process is the application of marking information, printing, to the encapsulated front surface of the resistor. This step is represented by block 64 in FIG. 2 . This is accomplished by transfer printing the necessary information on the front surface of the resistor with marking ink. The strip is then moved to the separating station represented by block 65 where the individual resistors are cut away from the carrier strip 24 . The individual resistors are plated with solder to create a solder coating 58 as shown in FIG. 7 A. The individual resistors 10 are then complete and they are attached to a plastic tape 68 at a packaging station represented by the numeral 66 .
The forming of the raised portion 34 can be accomplished at various stages of the manufacturing process as desired. For example, the raised portion can be roll formed before the strip 24 is placed on reel 22 , or it can be roll formed immediately after it is unwound from reel 22 . A further modified form of the method may involve waiting until after the separation step 42 and the adjust and calibrate step 60 before stamping the individual resistor blanks to create the raised portion 34 . The advantage of this later method is that the raised portion is not deformed or bent during the performance of the punching step 38 , the separating step 42 , or the adjust and calibration step 60 .
The preferred method for forming the transfer holes, for trimming the upper edge of the strip to length, and forming the separate resistor blanks is stamping or punching. However, other methods such as cutting with lasers, drilling, etching, and grinding may be used.
The preferred method for calibrating the resistor is to cut the resistor with a laser. However, punching, milling, grinding or other conventional means may be used.
The dielectric material used for the resistor is preferably a rolled high temperature coating, but various types of paint, silicon, and glass in the forms of liquid, powder, or paste may be used. They may be applied by molding, spraying, brushing, or static dispensing.
The solder that is applied may be a plating which is preferable or could also be a conventional solder paste or hot solder dip material.
The marking ink used for the resistor is preferably a white liquid, but various colors and types of marking ink may be used. They may be applied by transfer pad, ink jet, transfer roller. The marking may also be accomplished by use of a marking laser beam.
In the drawings and specification there has been set forth a preferred embodiment of the invention, and although specific terms are employed, these are used in a generic and descriptive sense only and not for purposes of limitation. Changes in the form and the proportion of parts as well as in the substitution of equivalents are contemplated as circumstances may suggest or render expedient without departing from the spirit or scope of the invention as further defined in the following claims.
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A surface mount resistor is formed from an elongated resistive body having first and second terminal ends and a raised center portion formed therebetween. The raised center portion includes slots in its edges which form a serpentine current path through the raised center portion of the resistor. A dielectric surrounds and encapsulates the raised center portion and an electrically conductive material coats the first and second terminal ends. The method for manufacturing involves utilizing an elongated ribbon which is of unitary construction and which is formed to create a carrier strip and a raised center portion for the resistors ultimately to be formed.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based on Japanese Patent Application No. 2013-263348 filed on Dec. 20, 2013, the disclosure of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The present disclosure relates to an electronic control unit.
BACKGROUND
[0003] In automobiles, a large number of in-vehicle apparatuses, such as brake, steering, and engine, are electronically controlled by an electronic control unit. In conjunction with the proliferation of electric vehicles and hybrid vehicles, it is expected that the targets of electronic control, such as motor control and battery control, will be increased in the future. For this reason, ISO 26262, a functional safety standard for automobiles was established to ensure safety when an automobile is electronically controlled.
[0004] In ISO 26262, each electronically controlled system is ranked based on a hazardous event (hazard) that may occur when the functions of the system become faulty. This ranking is carried out by three parameters, hazard level, the frequency of occurrence, and controllability (the degree of difficulty of avoidance) using an index called ASIL (Automotive Safety Integrity Level). As ASIL, five ranks, QM (Quality Management), A, B, C, and D in ascending order of risk, are laid down. A designer of a system is required to determine to which rank the system is equivalent and take a safety measure corresponding to the determined rank.
[0005] A case where some system is ranked “C” of ASIL will be taken as an example. In this case, as described in Patent Document 1, the following configuration may be adopted: a configuration in which the electronic control unit electronically controlling that system is divided into three levels and the operation at a higher level is monitored at a lower level. In this electronic control unit in Patent Document 1, the first level is in charge of the control functions of the system. Specifically, at the first level, determination is made with respect to fuel supply to an internal combustion engine or the adjustment of ignition timing. At the second level, the correctness of the performance of the control functions at the first level is inspected based on a selected input/output signal. At the third level, the monitoring carried out at the second level is inspected. Specifically, for example, a RAM test, a ROM test, a performance test, and the like are carried out. A watchdog is provided for this performance test at the third level.
[0006] When a system is ranked some rank of ASIL as mentioned above, hardware and software are designed to take a safety measure corresponding to that rank in the electronic control unit. Therefore, it is required to redesign the hardware and software of the electronic control unit so as to meet safety requirements according to a higher ASIL rank in the following cases: a case where a system of a higher ASIL rank than an existing system is newly integrated; and a case where the ASIL rank of a system is changed to a higher rank because of a difference in the vehicle equipped with the system or the like. In these cases, there is the possibility that the development cost will be increased.
[0007] Patent Document 1: Japanese Patent No. 3957749 (corresponding to U.S. Pat. No. 5,880,568 A)
SUMMARY
[0008] It is an object of the present disclosure to provide an electronic control unit in which safety requirements according to a higher ASIL rank can be met without any significant design change.
[0009] According to an aspect of the present disclosure, an electronic control unit electronically controls a system, which provides a safety function having a high-order automotive safety integrity level, and provides a plurality of safety mechanisms having a plurality of low-order automotive safety integrity levels respectively, which are decomposed from the high-order automotive safety integrity level. The electronic control unit includes: a plurality of central processing units including a first central processing unit and a second central processing unit; a memory that is commonly utilized by the plurality of central processing units; and an anti-interference device. Each of the first central processing unit and the second central processing unit executes a first monitoring function and a second monitoring function as a safety mechanism according to the low-order automotive safety integrity levels, respectively. The first monitoring function provides to monitor whether a control function of the system is properly executed. The second monitoring function provides to monitor whether the first monitoring function is properly executed. The memory have a first area, which is utilized by the first central processing unit to execute each of the first monitoring function and the second monitoring function, and a second area, which is utilized by the second central processing unit to execute each of the first monitoring function and the second monitoring function. The first area is different from the second area. The anti-interference device executes at least one of a prevention of an interference and a record of a history of the interference. The interference includes a first interference, which is provided to the second area by the first central processing unit when the first central processing unit executes each of the first monitoring function and the second monitoring function, and a second interference, which is provided to the first area by the second central processing unit when the second central processing unit executes each of the first monitoring function and the second monitoring function.
[0010] In the above case, as mentioned above, first, a higher-order safety integrity level is decomposed into a plurality of lower-order safety integrity levels by utilizing the concept of decomposition in ISO 26262. For example, ASIL-D can be decomposed into ASIL-C and ASIL-A, and ASIL-C can be decomposed into ASIL-B and ASIL-A. As mentioned above, decomposition can be utilized to lower the rank of a safety integrity level. For this reason, when a safety mechanism is built for a system required to ensure functional safety according to a higher-order safety integrity level, the following can be implemented: it is possible to enhance the reusability of hardware and software designed to meet safety requirements according to a lower-order safety integrity level.
[0011] When decomposition is carried out, however, it is required to ensure the independence of decomposed elements. To do this, a safety mechanism based on decomposed lower-order safety integrity levels could be individually built in independent separate electronic control units. However, use of separate electronic control units as mentioned above involves a problem of increased cost and physical size.
[0012] In the above case, consequently, an electronic control unit having a plurality of CPUs including a first CPU and a second CPU is used. Each of the first CPU and the second CPU carries out the following functions as a safety mechanism based on a plurality of decomposed lower-order safety integrity levels: a first monitoring function for monitoring whether the control function of the system is correctly carried out; and a second monitoring function for monitoring whether the first monitoring function is correctly working. This makes it possible to ensure a certain measure of independence as a safety mechanism based on the decomposed lower-order safety integrity levels.
[0013] In case of a single electronic control unit, even though a plurality of CPUs are provided, memories are used by the CPUs in a shared manner. Therefore, should data required for the execution of a monitoring function by one safety mechanism be read or rewritten in conjunction with the execution of a monitoring function by the other safety mechanism, the following takes place: there is the possibility that a monitoring function will not correctly work. To cope with this, in the present case, an anti-interference device is provided, to prevent the following interference or to record the history of occurrence of interference: interference with the second area of a memory in conjunction with the execution of each monitoring function by the first CPU; and interference with the first area of a memory in conjunction with the execution of each monitoring function by the second CPU. As a result, it is possible to prevent the occurrence of the above-mentioned event and cause each monitoring function to correctly work without fail. Or, when interference occurs, the history thereof can be kept; therefore, a safety measure, such as system stop, can be taken.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The above and other objects, features and advantages of the present disclosure will become more apparent from the following detailed description made with reference to the accompanying drawings. In the drawings:
[0015] FIG. 1 is a block configuration diagram illustrating the functions carried out by each CPU of an electronic control unit in an embodiment on a block-by-block basis;
[0016] FIG. 2 is a configuration diagram illustrating major components of an electronic control unit;
[0017] FIG. 3 is a block configuration diagram illustrating the functions carried out by each CPU of an electronic control unit in a first modification on a block-by-block basis;
[0018] FIG. 4 is a block configuration diagram illustrating the functions carried out by each CPU of an electronic control unit in a second modification on a block-by-block basis; and
[0019] FIG. 5 is a block configuration diagram illustrating the functions carried out by each CPU of an electronic control unit in a third modification on a block-by-block basis.
DETAILED DESCRIPTION
[0020] Hereafter, a description will be given to an electronic control unit in an embodiment of the present disclosure with reference to the drawings. In the following description, common components will be marked with the same reference numerals and a description thereof may be omitted.
[0021] FIG. 1 illustrates the functions carried out by each CPU 11 , 21 of the electronic control unit (microcomputer) 10 on a block-by-block basis. FIG. 2 illustrates major components of the microcomputer 10 .
[0022] The microcomputer 10 in this embodiment is for electronically controlling an in-vehicle apparatus, such as brake, steering, and engine. For example, when the microcomputer 10 electronically controls a braking device, it controls the breaking pressure applied to each wheel by the braking device to prevent the occurrence of locking during braking or slipping during acceleration. When the microcomputer 10 electronically controls a power steering device, it controls the device so that appropriate auxiliary steering torque acts on the steering shaft. When the microcomputer 10 electronically controls an engine, it controls a fuel injection valve or an ignition coil so that fuel injection or ignition is appropriately carried out based on the operating state of the vehicle. The electronic control unit may electronically control any other in-vehicle apparatus.
[0023] Such a system electrically controlling an in-vehicle apparatus as described above is required to meet a functional safety standard established as ISO 26262. A case where the ASIL rank of an existing system is ASIL-C and the ASIL rank of a system newly integrated into the existing system is ASIL-D higher than it will be taken as an example. In this case, it is required to redesign the hardware and software of the electronic control unit to meet the safety requirements according to the higher ASIL rank. A case where the ASIL rank of an existing system is ASIL-C but the ASIL rank is changed to ASIL-D because of a difference in the applied car model or the like will be taken as an example. Also in this case, it is similarly required to redesign the hardware and software of the electronic control unit. However, when the hardware and software of the electronic control unit are entirely redesigned, a large amount of labor is required and this increases the development cost.
[0024] Consequently, this embodiment is so configured that safety requirements according to a higher-order ASIL rank can be met without entirely redesigning the hardware or software of the electronic control unit.
[0025] For this purpose, in this embodiment, an electronic control unit having a plurality of CPUs including a first CPU 11 and a second CPU 21 is used as illustrated in FIG. 1 . Though FIG. 1 depicts only two CPUs, the number of CPUs may be three or more.
[0026] Utilizing the concept of decomposition in ISO 26262, a higher-order safety integrity level is decomposed into a plurality of lower-order safety integrity levels; and safety mechanisms according to the decomposed lower-order safety integrity levels are incorporated into each of the first CPU 11 and the second CPU 21 . FIG. 1 shows an example in which ASIL-D is decomposed into ASIL-C(D) and ASIL-A(D) and a safety mechanism of ASIL-C(D) is incorporated into the first CPU 11 and a safety mechanism of ASIL-A(D) is incorporated into the second CPU 21 .
[0027] As mentioned above, the rank of a safety integrity level can be lowered by utilizing decomposition. For this reason, when a safety mechanism is built for a system required to ensure functional safety according to a higher-order safety integrity level, the following can be implemented: the reusability of hardware and software designed to meet safety requirements according to a lower-order safety integrity level can be enhanced.
[0028] Hereafter, a detailed description will be given to the example illustrated in FIG. 1 and technical features of the electronic control unit in this embodiment will be thereby further made apparent.
[0029] As illustrated in FIG. 1 , the first CPU 11 has a three-level structure. At the first level of the first CPU 11 , a first function 12 and a second function 13 are allocated. For example, the first function 12 is a control function for controlling an existing system and the second function 13 is a control function for controlling a new system integrated into the existing system. The ASIL rank for the first function 12 is ASIL-C and the ASIL rank for the second function is ASIL-D.
[0030] A program for carrying out the first function 12 and the second function 13 is stored in a predetermined area in the ROM 27 shown in FIG. 2 . The first CPU 11 reads the program and carries out processing and each function of the first function 12 and the second function 13 is thereby carried out. At this time, the first CPU 11 writes and reads data using a predetermined area in the RAM 26 shown in FIG. 2 as a work memory.
[0031] At the second level of the first CPU 11 , a first monitoring function 14 and a second monitoring function 15 are allocated as illustrated in FIG. 1 . The first monitoring function 14 is for monitoring whether the first function 12 required to meet the ASIL-C safety integrity level is correctly working. The second monitoring function 15 is for monitoring the following according to ASIL-C(D) which is one of safety integrity levels, ASIL-C(D) and ASIL-A(D), decomposed from ASIL-D, the safety integrity level required of the second function 13 : whether the second function 13 is correctly working. Similarly to the first function 12 and the second function 13 , the first monitoring function 14 and the second monitoring function 15 are also comprised of programs that can be executed by the first CPU 11 . The programs for carrying out the first monitoring function 14 and the second monitoring function 15 are stored in an area in the ROM 27 different from the storage area for the programs of the first function 12 and the second function 13 . When the first CPU 11 executes programs of the first monitoring function 14 and the second monitoring function 15 , it writes and reads data using the following predetermined area as a work memory: a predetermined area, different from the area for carrying out the first function 12 and the second function 13 , in the RAM 26 shown in FIG. 2 .
[0032] An example of the concrete detail of programs for carrying out the first monitoring function 14 and the second monitoring function 15 is as described below. The same sensor signals as to the first function 12 and the second function 13 are inputted and the same processing as the first function 12 and the second function 13 is executed to calculate a monitoring control target value. The calculated monitoring control target value is compared with the respective control target values calculated by the first function 12 and the second function 13 . In this comparison, the first monitoring function 14 and the second monitoring function 15 determine whether or not the first function 12 and the second function 13 are correctly working according to the following: whether or not the monitoring control target value agrees with the control target values calculated by the first function 12 and the second function 13 . Specifically, when the monitoring control target value and the control target values agree with each other, it is determined that the first function 12 and the second function 13 are correctly working; and when they disagree from each other, it is determined that the functions are not correctly working. When it is determined that the first function 12 and the second function 13 are not correctly working, the first monitoring function 14 and the second monitoring function 15 output a stop signal to, for example, a drive circuit, not shown. They thereby stop the output of a driving signal to a device to be controlled based on the control target value.
[0033] At the third level of the first CPU 11 , a third monitoring function 16 is allocated as illustrated in FIG. 1 . The third monitoring function 16 is for monitoring whether or not each of the first monitoring function 14 and the second monitoring function 15 is correctly working. Similarly to the first function 12 and second function 13 and the first monitoring function 14 and second monitoring function 15 , the third monitoring function 16 is also comprised of programs that can be executed by the first CPU 11 . The programs comprising the third monitoring function 16 are stored in the following area in the ROM 27 : an area different from the storage areas for the programs of the first function 12 and second function 13 and the first monitoring function 14 and second monitoring function 15 . When the first CPU 11 executes programs of the third monitoring function 16 , it writes and reads data using the following area in the RAM 26 as a work memory: a predetermined area different from the areas for carrying out the first function 12 , second function 13 , first monitoring function 14 , and second monitoring function 15 .
[0034] For example, the third monitoring function 16 determines whether programs comprising the first monitoring function 14 and the second monitoring function 15 are executed at the first CPU 11 in accordance with a correct procedure. This determination is made based on a signal outputted from the first monitoring function 14 and the second monitoring function 15 at each check point. Or, the third monitoring function 16 may determine the following like well-known watchdog timers: whether or not programs comprising the first monitoring function 14 and the second monitoring function 15 are being correctly carried out. This determination is made according to whether or not a signal is periodically outputted from the first monitoring function 14 and the second monitoring function 15 . Or, the following may be determined based on a ROM value or a RAM value in the areas used by the first monitoring function 14 and the second monitoring function 15 : whether or not each of the first monitoring function 14 and the second monitoring function 15 is correctly working.
[0035] When the third monitoring function 16 detects any anomaly in the first monitoring function 14 or the second monitoring function 15 , for example, the following takes place: it resets the first monitoring function 14 and the second monitoring function 15 or outputs a stop signal to the above-mentioned drive circuit.
[0036] A monitoring IC 17 determines whether the first CPU 11 is correctly operating or any anomaly has occurred through monitoring the third monitoring function 16 . When an anomaly has occurred, it resets the first CPU 11 . When the first CPU 11 is reset, it is desirable that the monitoring IC 17 should simultaneously output a stop signal to the above-mentioned drive circuit.
[0037] For example, the electronic control device is so configured that when the first CPU 11 is correctly executing programs of the third monitoring function 16 , the following takes place: a signal varied in predetermined order is outputted from the first CPU 11 to the monitoring IC 17 . With this configuration, the monitoring IC 17 can determine the following when a signal outputted from the first CPU 11 is varying in predetermined order: that the first CPU 11 is correctly executing programs of the third monitoring function 16 . Meanwhile, when a signal outputted from the first CPU 11 is not varying in predetermined order, the monitoring IC 17 can determine that: the first CPU 11 is not correctly executing programs of the third monitoring function 16 and an anomaly has occurred in the first CPU 11 .
[0038] A description will be given to the second CPU 21 . In the second CPU 21 , a safety mechanism according to ASIL-A(D) of the decomposed safety integrity levels is incorporated. The second CPU 21 has a two-level structure. At the first level of the second CPU 21 , as illustrated in FIG. 1 , a fourth monitoring function 22 is allocated. The fourth monitoring function 22 monitors the following according to ASIL-A(D), one of the decomposed safety integrity levels: whether the second function 13 is correctly working. Similarly to the first monitoring function 14 and the second monitoring function 15 , the fourth monitoring function 22 is also comprised of programs that can be executed by the second CPU 21 . The programs for carrying out the fourth monitoring function 22 are stored in an area, different from the storage areas for the programs of the other control functions and monitoring functions, in ROM 27 . When the second CPU 21 executes programs of the fourth monitoring function 22 , it writes and reads data using the following predetermined area in the RAM 26 as a work memory: a predetermined area different from the areas for carrying out the other control functions and monitoring functions.
[0039] As a concrete example, the fourth monitoring function 22 can be so configured that the following processing is executed: similarly to the first monitoring function 14 and the second monitoring function 15 , the same sensor signal as to the second function 13 is inputted to calculate a monitoring control target value; and it is compared with the control target value calculated by the second function 13 . However, the fourth monitoring function 22 is not required so strictly to meet a safety integrity level as the second monitoring function 15 is; therefore, the fourth monitoring function 22 may calculate a monitoring control target value by, for example, simpler processing than in the second monitoring function 15 . When processing is simplified as mentioned above, it is required to take an error arising from the simplification into account when the control target value and the monitoring control target value are compared with each other. That is, even though the control target value and the monitoring control target value are different from each other, the fourth monitoring function 22 determines that the second function 13 is correctly working as long as the difference falls within an error range.
[0040] At the second level of the second CPU 21 , as illustrated in FIG. 1 , a fifth monitoring function 23 is allocated. The fifth monitoring function 23 is for monitoring whether or not the fourth monitoring function 22 is correctly working. Similarly to the fourth monitoring function 22 , the fifth monitoring function 23 is also comprised of programs that can be executed by the second CPU 21 . The programs comprising the fifth monitoring function 23 are stored in an area, different from the storage areas for the programs of the other control functions and monitoring functions, in ROM 27 . When the second CPU 21 executes programs of the fifth monitoring function 23 , it writes and reads data using the following predetermined area in RAM 26 as a work memory: a predetermined area different from the areas for carrying out the other control functions and monitoring functions. The method for the fifth monitoring function 23 to determine whether the fourth monitoring function 22 is correctly working is the same as the above-mentioned method for the third monitoring function 16 and a description thereof will be omitted.
[0041] A watchdog timer (WDT) 24 determines whether the second CPU 21 is correctly operating or any anomaly has occurred through monitoring the fifth monitoring function 23 ; and when an anomaly has occurred, it resets the second CPU 21 . When the second CPU 21 is correctly executing programs of the fifth monitoring function 23 , a watchdog pulse is outputted from the second CPU 21 to WDT 24 at predetermined time intervals. Therefore, when a watchdog pulse is outputted from the second CPU 21 at predetermined time intervals, WDT 24 can determine that the second CPU 21 is correctly executing programs of the fifth monitoring function 23 . Meanwhile, when a watchdog pulse is not outputted from the second CPU 21 at predetermined time intervals, WDT 24 can determine that: the second CPU 21 is not correctly executing programs of the fifth monitoring function 23 and an anomaly has occurred in the second CPU 21 .
[0042] When the concept of decomposition is utilized to decompose a higher-order safety integrity level into a plurality of lower-order safety integrity levels, it is required to ensure the independence of decomposed elements. With respect to this, in this embodiment, safety mechanisms according to the decomposed lower-order safety integrity levels are respectively incorporated into independent separate first CPU 11 and second CPU 21 and it is possible to ensure a certain measure of independence.
[0043] However, when the CPUs, such as the first CPU 11 and the second CPU 21 , are provided in a single microcomputer 10 , the following takes place: these CPUs (first CPU 11 and second CPU 21 ) use RAM 26 and ROM 27 as memories in a shared manner as illustrated in FIG. 2 . Therefore, should data required for the execution of a monitoring function by one safety mechanism be read or rewritten during the execution of a monitoring function by the other safety mechanism and interference occur, the following takes place: there is the possibility that a monitoring function will not correctly work. To cope with this, in this embodiment, a memory protection unit (i.e., MPU) 25 is provided between the CPUs 11 , 21 and RAM 26 and ROM 27 as illustrated in FIG. 2 . The memory areas for each monitoring function are thereby protected against interference. The MPU 25 functions as an anti-interference device.
[0044] For example, MPU 25 sets the ranges indicated by alternate long and short dashed lines in FIG. 1 as a range to be protected against interference. That is, MPU 25 inhibits a control function or a monitoring function other than the first monitoring function 14 from doing the following: reading from the ROM area in which the programs of the first monitoring function 14 are stored; and writing and reading data to and from the RAM area specified as the work area for the first monitoring function 14 . Similarly, MPU 25 also inhibits the second monitoring function 15 to the fifth monitoring function 23 from doing the following: accessing the memory areas in RAM 26 and ROM 27 ensured for the execution of each monitoring function in conjunction with the execution of other control functions or monitoring functions. This makes it possible to prevent the occurrence of interference and cause each monitoring function to correctly work without fail.
[0045] As a result, it is possible to prevent interference with the memory areas ensured for the execution of the fourth monitoring function 22 and the fifth monitoring function 23 in conjunction with the following: the execution of the second monitoring function 15 or the third monitoring function 16 by the first CPU 11 . Further, it is also possible to prevent interference with the memory areas ensured for the execution of the second monitoring function 15 and the third monitoring function 16 in conjunction with the following: the execution of the fourth monitoring function 22 or the fifth monitoring function 23 by the second CPU 21 . Therefore, it is possible to prevent mutual interference between monitoring functions as safety mechanisms according to decomposed lower-order safety integrity levels without fail and thus it is possible to ensure mutual independence.
[0046] Up to this point, a description has been given to a preferred embodiment of the present disclosure. However, the present disclosure is not limited to the above embodiment at all and can be variously modified and embodied without departing from the subject matter of the present disclosure.
[0047] (First Modification)
[0048] An example will be taken. In the above-mentioned embodiment, using MPU 25 , the following is inhibited with respect to each monitoring function: accessing a memory area in RAM 26 or ROM 27 ensured for the execution of each monitoring function in conjunction with the execution of other control functions or monitoring functions. Instead, a measure against interference can also be taken without use of MPU 25 . For example, the following function is incorporated into the programs of each monitoring function: a function of, when data is written to a set RAM area, writing the same data to a plurality of locations (identical data writing device). In addition, the following functions are incorporated into some of the programs: a function of determining the identity of data at the locations (determination device); a function of, when it is determined that the identity of data has been lost, inhibiting rewriting the relevant data and keeping the history of interference; and a failsafe function of resetting a higher-order function or outputting a stop signal to a drive circuit according to the history of interference. This also makes it possible to take a measure against interference with respect to each monitoring function.
[0049] (Second Modification)
[0050] In the above-mentioned embodiment, the WDT 24 built in the microcomputer 10 is utilized to detect whether or not the second CPU 21 is correctly operating. When there is the very low possibility that the second CPU 21 and WDT 24 simultaneously become faulty due to a common cause, it is possible to use the WDT 24 built in the microcomputer 10 as in the above embodiment. However, in consideration of more reliably avoiding the occurrence of a fault due to a common cause, it is desirable that WDT 24 should be separately provided outside the microcomputer 10 as illustrated in FIG. 3 .
[0051] (Third Modification)
[0052] In the above-mentioned embodiment, the first CPU 11 carries out the following functions: the first function 12 that is a control function for controlling an existing system and the second function 13 that is a control function for controlling a new system integrated into the existing system. Further, it carries out each monitoring function as a safety mechanism therefor.
[0053] Instead, only the following functions may be incorporated into the first CPU 11 as illustrated in FIG. 4 : the second function 13 requiring a safety measure according to a higher-order safety integrity level (for example, ASIL-D); and each monitoring function as a safety mechanism according to one (for example, ASIL-C(D)) of the decomposed safety integrity levels. Further, as illustrated in FIG. 5 , WDT 24 may be separately provided outside the microcomputer 10 based on the configuration in FIG. 4 .
[0054] The electronic control unit may be so configured that the second function 13 is carried out at CPU different from the first CPU 11 and the second CPU 21 ; and only each monitoring function as a safety mechanism may be incorporated in the first CPU 11 and the second CPU 21 .
[0055] (Fourth Modification)
[0056] In the description of the above embodiment, a case where ASIL-D as a higher-order safety integrity level is decomposed into ASIL-C(D) and ASIL-A(D) has been taken as an example. The present disclosure is also applicable to a case where, for example, ASIL-C is decomposed into ASIL-B(C) and ASIL-A(C) and other like cases.
[0057] While the present disclosure has been described with reference to embodiments thereof, it is to be understood that the disclosure is not limited to the embodiments and constructions. The present disclosure is intended to cover various modification and equivalent arrangements. In addition, while the various combinations and configurations, other combinations and configurations, including more, less or only a single element, are also within the spirit and scope of the present disclosure.
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An ECU for controlling a system providing a safety function with a high-order ASIL and for providing safety mechanisms with low-order ASILs includes: CPUs including first and second CPUs; a memory; and an anti-interference device. Each CPU executes first and second monitoring functions according to the low-order ASILs. The first monitoring function provides to monitor whether a control function of the system is properly executed, and the second monitoring function provides to monitor whether the first monitoring function is properly executed. The memory has a first area for the first CPU and a second area for the second CPU. The anti-interference device executes a prevention of an interference or a record of a history of the interference. The interference includes a first interference provided to the second area by the first CPU and a second interference provided to the first area by the second CPU.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Korean Patent Application No. 2007-54985, filed on Jun. 5, 2007 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND
[0002] 1. Field
[0003] The present invention relates to a washing machine including a balancer, and more particularly, to a washing machine capable of reducing a vibration of a water tub due to an eccentric state, that is, an unbalance, which may occur at the time of rotation of a rotation tub, and a method of controlling the same.
[0004] 2. Description of the Related Art
[0005] In general, a washing machine (generally, a drum-shaped washing machine) includes a water tub which contains water (washing water or rinsing water) therein, a rotation tub which is rotatably installed in the water tub and contains laundry therein, and a motor which generates a driving force to rotate the rotation tub. The washing machine washes the laundry by an operation of rising and dropping the laundry contained therein along an inner wall of the rotation tub when the cylindrical rotation tub is rotated.
[0006] Such a washing machine washes the laundry using a series of operations including a washing mode to wash dirt out of the laundry using water in which a detergent is dissolved (i.e., washing water), a rinsing mode to rinse bubble or residual detergent out of the laundry using water in which the detergent is not dissolved (i.e., rinsing water), and a dehydrating mode to dehydrate the laundry at a high speed. In the dehydrating mode, if the rotation tub is rotated at a high speed in a state in which the laundry is unevenly distributed along an inner wall of the rotation tub and thus an unbalance or imbalance occurs, a force is biased toward a rotation shaft of the rotation tub to generate a large vibration.
[0007] In order to prevent the vibration due to such an unbalance, a washing machine including a race which is provided to be concentric with a rotation tub and a balancer having a plurality of balls seated in the race together with oil is disclosed in Japanese Unexamined Patent Application Publication No. 10-43472.
[0008] In the washing machine disclosed in the above Publication, when the rotation tub is rotated at a high speed, the balls are automatically moved in the race to prevent the force from being biased toward the rotation shaft such that the unbalance is removed.
[0009] However, in the washing machine including the balancer as described above, if the weight of the unbalance is larger than the total weight of the balls, the unbalance cannot be sufficiently removed even if the balls are located opposite the unbalance in the circumferential direction (opposite phase). Thus, the vibration occurs.
[0010] If the number of rotations of the rotation tub is less than an inherent number of vibrations of the rotation tub, a difference occurs between a movement speed of the balls and a movement speed of the unbalance (i.e., the rotation speed of the rotation tub), and thus a relative position between the unbalance and the balls periodically varies.
[0011] At this time, if the balls and the unbalance are arranged in phase with each other in the circumferential direction (in-phase), a larger force is applied to the rotation shaft to generate a larger vibration. If the balls and the unbalance are arranged in phase with each other at a time point when the number of rotations of the rotation tub coincides with the inherent number of vibrations, resonance becomes large enough to generate an excessive vibration of the water tub.
SUMMARY
[0012] Therefore, it is an aspect of the embodiment to provide a washing machine including a balancer, which increases a speed of a rotation tub stepwise in a period in which an excessive vibration of a water tub occurs to pass an excessive vibration period without the vibration, and a method of controlling the same.
[0013] It is another aspect of the embodiment to provide a washing machine capable of preventing rapid movement of balls to prevent an excessive vibration of a water tub by detecting an unbalance state in real time while a speed of a rotation tub is increased stepwise and by increasing the speed of the rotation tub when the amount of unbalance is less than or equal to a restriction value, and a method of controlling the same.
[0014] Additional aspects and/or advantages will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
[0015] In accordance with the invention, the above and/or other aspects can be achieved by the provision of a method of controlling a washing machine including a water tub, a rotation tub and at least one balancer, the method including: increasing a speed of a rotation tub stepwise in a period in which an excessive vibration of the water tub occurs; measuring current of a motor to detect an amount of unbalance while the speed of the rotation tub is increased stepwise; and controlling the speed of the rotation tub based on the detected amount of unbalance.
[0016] The speed of the rotation tub which is increased stepwise may be divided into a plurality of RPM ranges in the period in which the excessive vibration of the water tub occurs, and the speed of the rotation tub may be increased stepwise based on the plurality of RPM ranges.
[0017] When the speed of the rotation tub is increased stepwise to reach a predetermined RPM, the speed of the rotation tub may be maintained at the predetermined RPM, and a time in which the speed of the rotation tub is maintained at the predetermined RPM may be counted, and the speed of the rotation tub may be increased after a lapse of a predetermined amount of time.
[0018] The predetermined RPM may be the speed of the rotation tub in which an unbalance is able to occur.
[0019] The predetermined time may be a reference time necessary to remove the unbalance by the at least one balancer.
[0020] The speed of the rotation tub which is increased stepwise may be divided into a plurality of RPM ranges in the period in which the excessive vibration of the water tub occurs, and the speed of the rotation tub may be increased when the amount of unbalance is equal to or less than a predetermined restriction value based on the plurality of RPM ranges.
[0021] The rotation tub may be stopped when the amount of unbalance is greater than the restriction value.
[0022] The excessive vibration period of the water tub may be approximately 160 to 300 RPM.
[0023] The foregoing and/or other aspects are achieved by providing a method of controlling a washing machine including a rotation tub, a motor and at least one balancer, the method including: dividing a speed of the rotation tub stepwise in a predetermined period; increasing the speed of the rotation tub divided stepwise to reach a predetermined RPM and maintaining the speed of the rotation tub at the predetermined RPM, and counting a time in which the speed of the rotation tub is maintained at the predetermined RPM and increasing the speed of the rotation tub after a lapse of a predetermined amount of time.
[0024] Current of the motor may be measured to detect an amount of unbalance while the speed of the rotation tub is increased stepwise, and the speed of the rotation tub may be increased when the detected amount of unbalance is equal to or less than a predetermined restriction value.
[0025] The rotation tub may be stopped when the amount of unbalance is greater than the restriction value.
[0026] The foregoing and/or other aspects are achieved by providing a washing machine including at least one balancer, the washing machine including: a rotation tub to contain laundry therein; a motor rotating the rotation tub; and a control unit driving the motor to increase a speed of the rotation tub stepwise, measuring current of the motor to detect an amount of unbalance while the speed of the rotation tub is increased stepwise, and controlling the speed of the rotation tub based on the detected amount of unbalance.
[0027] The control unit may divide the speed of the rotation tub, which is increased stepwise, into a plurality of RPM ranges and increase the speed of the rotation tub stepwise based on the plurality of RPM ranges.
[0028] The washing machine may further include a speed detecting unit detecting the speed of the rotation tub which is increased stepwise, and the control unit may control the driving of the motor such that the speed of the rotation tub is maintained at a predetermined RPM when the speed of the rotation tub reaches the predetermined RPM in which an unbalance is able to occur.
[0029] The control unit may count a time in which the speed of the rotation tub is maintained at the predetermined RPM and control the driving of the motor such that the speed of the rotation tub is increased after a lapse of a predetermined amount of time.
[0030] The control unit may divide the speed of the rotation tub, which is increased stepwise, to a plurality of RPM ranges and control the driving of the motor such that the speed of the rotation tub is increased when an amount of unbalance is equal to or less than a predetermined restriction value based on the plurality of RPM ranges.
[0031] The rotation tub may be stopped when the amount of unbalance is greater than the restriction value.
[0032] The washing machine may further include a water tub, and the control unit may control the driving of the motor such that the speed of the rotation tub is increased stepwise in a period in which an excessive vibration of the water tub occurs.
[0033] The foregoing and/or other aspects are achieved by providing a method of controlling a washing machine including a water tub, a rotation tub and at least one balancer, the method including: detecting an amount of unbalance in an excessive vibration period of the water tub; and increasing a speed of a rotation tub stepwise when the detected amount of unbalance is less than or equal to a restriction value.
[0034] The speed of the rotation tub may be divided into a plurality of RPM ranges in the excessive vibration period of the water tub and the speed may be increased stepwise based on the plurality of RPM ranges.
[0035] The speed of the rotation tub may be maintained at a first speed within each of the RPM ranges and then increased to a second speed within each of the RPM ranges, the speed of the rotation tub being maintained at the first speed until a time in which the speed of the rotation tub is maintained at the first speed reaches a reference time necessary to remove the unbalance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] These and/or other aspects and advantages will become apparent and more readily appreciated from the following description of the embodiment, taken in conjunction with the accompanying drawings of which:
[0037] FIG. 1 is a cross-sectional view showing the configuration of a washing machine including balancers according to the present embodiment;
[0038] FIG. 2 is an exploded perspective view of a rotation tub according to the present embodiment;
[0039] FIG. 3 is a coupled perspective view of the rotation tub according to the present embodiment;
[0040] FIG. 4 is a block diagram showing a control configuration of the washing machine including the balancers according to the present embodiment;
[0041] FIG. 5 is a waveform diagram showing a generation of a vibration of a water tub due to a difference in rotation speed between the rotation tub and balls in the washing machine including the balancers according to the present embodiment;
[0042] FIG. 6 is a view showing a difference in rotation speed between the rotation tub and the balls in the washing machine including the balancers according to the present embodiment;
[0043] FIG. 7 is a graph showing a speed profile in a dehydrating mode of the washing machine including the balancers according to an embodiment of the present embodiment;
[0044] FIG. 8 is a table showing an excessive vibration controlling process stepwise in the washing machine including the balancers according to the present embodiment;
[0045] FIG. 9 is a flowchart illustrating the excessive vibration controlling process of the washing machine including the balancers according to the present embodiment;
[0046] FIG. 10 is a graph showing a relationship between the amount of unbalance and a speed in the excessive vibration controlling process of the washing machine including the balancers according to the present embodiment;
[0047] FIG. 11 is a graph showing a vibration value when the speed is increased at once in the excessive vibration period of the water tub;
[0048] FIG. 12 is a graph showing a vibration value when the speed is increased stepwise in the excessive vibration period of the water tub;
[0049] FIG. 13 is a graph showing a process capability obtained by repeatedly performing a vibration test in x and y axes 30 times and analyzing a maximum vibration value when the speed of the rotation tub is increased at once in the excessive vibration period of the water tub under a load condition of 80 percent of laundry;
[0050] FIG. 14 is a graph showing a process capability obtained by repeatedly performing a vibration test in the x and y axes 30 times and analyzing a maximum vibration value when the speed of the rotation tub is increased stepwise in the excessive vibration period of the water tub under the load condition of 80 percent of laundry.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0051] Reference will now be made in detail to the embodiment, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiment is described below to explain the present invention by referring to the figures.
[0052] FIG. 1 is a cross-sectional view showing the configuration of a washing machine including balancers according to the present embodiment.
[0053] In FIG. 1 , the washing machine including the balancers according to the present embodiment includes a water tub 20 which is installed in a housing 10 forming an external appearance of the washing machine and contains water therein, a rotation tub 30 which is rotatably installed in the water tub 20 and contains laundry therein, and a door 40 which is hinge-coupled to an open front surface of the housing 10 .
[0054] A water supplying valve 12 to supply water into the water tub 20 and a detergent supplying device 14 to supply a detergent into the water tub 20 are provided above the water tub 20 . A water draining pump 16 to drain water contained in the water tub 20 out of the housing 10 when an operation of washing the laundry is completed is provided below the water tub 20 .
[0055] A rotation shaft 51 is provided at a side of a rear surface of the rotation tub 30 to penetrate through a rear surface of the water tub 20 , and a motor 50 coupled to the rotation shaft 51 is provided outside the rear surface of the water tub 20 . Accordingly, when the motor 50 is operated, the rotation shaft 51 is rotated and thus the rotation tub 30 is rotated.
[0056] A plurality of dehydration holes 30 a is formed in a circumferential surface of the rotation tub 30 . In a washing mode, water which is contained in the water tub 20 flows into the rotation tub 30 through the dehydration holes such that the laundry is washed by water containing a detergent therein. In a dehydrating mode, water is drained from the housing 10 through the water draining pump 16 .
[0057] A plurality of lifters 30 b is provided in the rotation tub 30 in a vertical direction such that wet laundry is lifted up from a bottom of the rotation tub 30 and is lifted down to the bottom of the rotation tub 30 when the rotation tub 30 is rotated at a low speed in the washing mode. Thus, the laundry can be efficiently washed.
[0058] Accordingly, in the washing mode, the rotation tub 30 is rotated at a low speed while the rotation shaft 51 is alternately rotated forward and backward by the motor 50 , such that the laundry is washed. In the dehydrating mode, the rotation tub 30 is rotated at a high speed while the rotation shaft 51 is rotated in one direction, so that the laundry is dehydrated.
[0059] When the rotation tub 30 is rotated at the high speed in the dehydrating mode, if the center of gravity of the rotation tub 30 does not coincide with the center of rotation or the laundry is unevenly distributed in the rotation tub 30 such that an unbalance occurs in a specific portion, a force is biased toward the rotation shaft 51 of the rotation tub 30 and thus a dynamic balance of the rotation tub 30 is not maintained.
[0060] In order to prevent a dynamic unbalance such that the rotation tub 30 can be rotated at the high speed in a state in which the center of gravity of rotation tub 30 coincides with the center of rotation, balancers 60 are provided at a front end and a rear end of the rotation tub 30 .
[0061] FIG. 2 is an exploded perspective view of the rotation tub according to the present embodiment, and FIG. 3 is a coupled perspective view of the rotation tub according to the present embodiment.
[0062] In FIG. 2 , a front surface and a rear surface of the rotation tub 30 are opened. The rotation tub 30 includes a cylindrical main body 31 including the dehydration holes 30 a and the lifters 30 b , a front side member 32 which is coupled to the opened front surface of the main body 31 and has an opening 34 through which the laundry is put into the main body 31 and is taken out from the main body 31 , and a rear side member 33 which is coupled to the opened rear surface of the main body 31 and receives the rotation shaft 51 to rotate the rotation tub 30 .
[0063] An annular recess 35 which has a substantially U-shape in a cross section and is opened toward a front side of the washing machine is formed in the circumference of the front side member 32 to contain a balancer 60 therein. An annular recess (not shown) which is opened toward a rear side of the washing machine is formed in the circumference of the rear side member 33 to contain another balancer 60 therein.
[0064] The front side member 32 and the rear side member 33 are respectively fitted into the front circumference and the rear circumference of the main body 31 by a screwing method or other fixing method, as shown in FIG. 3 .
[0065] The balancers 60 are mounted in the recesses 35 of the front side member 32 and the rear side member 33 . Each of the balancers 60 is an annular single race and includes a plurality of balls 61 which is made of steel, for example, and has a balancing function and viscous fluid (not shown) to adjust the movement speed of the plurality of balls 61 .
[0066] The balls 61 are mounted to be moved in a circumferential direction. When the dynamic unbalance occurs in the rotation tub 30 , the balls 61 are moved in the circumferential direction to a position which is symmetrical to a position at which the dynamic unbalance occurs. Thus, the vibration of the rotation tub 30 can be reduced.
[0067] FIG. 4 is a block diagram showing the control configuration of the washing machine including the balancers according to the present embodiment.
[0068] In FIG. 4 , the washing machine according to the present embodiment includes an input unit 100 to allow a user to input an operation command including the setting of the dehydrating mode, a control unit 102 controlling the whole operation of the washing machine such as a washing mode, a rinsing mode and a dehydrating mode, a motor driving unit 104 driving the motor 50 to rotate the rotation tub 30 under the control of the control unit 102 , a speed detecting unit 106 to send a motor speed signal corresponding to the rotation speed of the rotation tub 30 to the control unit 102 , and a current detecting unit 108 to send a motor current signal corresponding to the rotation speed of the rotation tub 30 to the control unit 102 .
[0069] The washing machine according to the present embodiment further includes a vibration detecting unit 110 to detect the vibration in X and Y axes. The vibration detecting unit 110 detects the vibration of the water tub 20 which is generated before the balls 61 reach a balancing position in the washing machine including the balancers 60 , thereby obtaining a signal waveform of a vibration frequency shown in FIG. 5 .
[0070] FIG. 5 shows a signal waveform of the vibration frequency which is generated due to a modulation phenomenon due to a difference between the rotation speed (RPM 1 ) of the rotation tub 30 and the rotation speed (RPM 2 ) of the balls 61 shown in FIG. 6 .
[0071] The control unit 102 performs the dehydrating mode with a speed profile shown in FIG. 7 in order to dehydrate the laundry at a high speed without an excessive vibration of the water tub 20 .
[0072] FIG. 7 is a graph showing a speed profile of the washing machine including the balancers 60 according to the present embodiment at the time of the dehydrating mode.
[0073] In FIG. 7 , the dehydrating mode includes a laundry amount detecting process 1 of detecting the weight of the laundry at the time of starting of the dehydrating mode, a laundry disentangling process 2 of reversing the left and the right of the rotation tub 30 to disentangle the laundry, a laundry rolling process 3 of increasing the speed of the rotation tub 30 at a predetermined speed to stick the laundry to the inner wall of the rotation tub 30 , an unbalance detecting process 4 of detecting the amount of unbalance using a control parameter such as the weight of the laundry and the current of the motor 50 , an excessive vibration controlling process 5 of increasing the speed of the rotation tub 30 stepwise when the amount of unbalance detected in an excessive vibration period of the water tub 20 is less than a restriction value, and a high-speed dehydrating process 6 rotating the rotation tub 30 at a high speed and draining water contained in the laundry by a centrifugal force after increasing the speed of the rotation tub 30 stepwise and passing the excessive vibration period of the water tub 20 without the vibration.
[0074] The excessive vibration period of the water tub 20 indicates a period in which the speed of the rotation tub 30 is 160 to 300 RPM, for example. When the speed of the rotation tub 30 is in a range from 160 to 300 RPM, a mechanical resonance point exists and a large amount of water contained in the laundry is drained. Thus, the unbalance may occur. In addition, a phenomenon that the balls 61 are dispersed also occurs and a probability that the excessive vibration of the water tub 20 occurs is high. However, it is difficult to expect the phenomenon and the probability.
[0075] Accordingly, in the excessive vibration controlling process 5 of the present embodiment, the speed of the rotation tub 30 is not increased at once in the excessive vibration period of 160 to 300 RPM. That is, as shown in FIG. 8 , the excessive vibration controlling process 5 includes a first step 5 - 1 of maintaining a start point, that is, 160 RPM, of the excessive vibration period when the speed of the rotation tub 30 is increased after detecting the unbalance, a second step 5 - 2 of increasing the speed from 160 RPM to 210 RPM, a third step 5 - 3 of maintaining the speed of 210 RPM for approximately 10 seconds to prevent the balls 61 from being rapidly moved and positioned opposite the unbalance of the rotation tub 30 , a fourth step 5 - 4 of increasing the speed from 210 RPM to 260 RPM, a fifth step 5 - 5 of maintaining the speed of 260 RPM for approximately 10 seconds to prevent the balls from being rapidly moved and positioned opposite the unbalance of the rotation tub 30 , and a sixth step of 5 - 6 of increasing the speed from 260 RPM to 300 RPM, thereby increasing the speed of the rotation tub 30 stepwise such that the amount of unbalance is not rapidly changed. While the speed of the rotation tub 30 is increased stepwise, the amount of unbalance is detected in real time. If the amount of unbalance is less than or equal to a restriction limit, the speed of the rotation tub 30 is increased by the six steps such that the rapid movement of the balls 61 is prevented to pass the excessive vibration period of the water tub 20 without the vibration.
[0076] In the excessive vibration controlling process 5 of the present embodiment, the amount of unbalance is always detected in real time and the rotation tub 30 is stopped when the amount of unbalance is greater than the restriction value.
[0077] Hereinafter, the operation and effect of the washing machine and the method of controlling the same will be described.
[0078] FIG. 9 is a flowchart illustrating the excessive vibration controlling process of the washing machine including the balancers according to the present embodiment, that is, a method of dehydrating the laundry at a high speed while passing an excessive vibration period of the water tub 20 without the vibration in the dehydrating mode.
[0079] When a user puts the laundry W into the rotation tub 30 and inputs an operation command including the setting of the dehydrating mode through the input unit 100 , the control unit 102 performs the series of operations including the washing mode, the rinsing mode and the dehydrating mode.
[0080] Accordingly, the control unit 102 determines whether the mode becomes the dehydrating mode ( 200 ). If it is determined that the mode becomes the dehydrating mode, the laundry amount detecting process 1 of detecting the weight of the laundry W is performed as shown in FIG. 7 ( 202 ), in order to use the weight of the laundry W as basic information to detect the amount of unbalance or determine an allowable amount of unbalance before the high-speed dehydrating process.
[0081] After the laundry amount detecting process 1 , the control unit 102 performs the laundry disentangling process 2 of controlling the driving of the motor 50 through the motor driving unit 104 and reversing to the left and the right of the rotation tub 30 to disentangle the laundry W as shown in FIG. 7 ( 204 ).
[0082] After the laundry disentangling process 2 , the control unit 102 performs the laundry rolling process 3 of increasing the speed of the rotation tub 30 to the predetermined speed and sticking the laundry W to the inner wall of the rotation tub 30 as shown in FIG. 7 ( 206 ).
[0083] After the laundry rolling process 3 , the control unit 102 performs the unbalance detecting process 4 of detecting the amount of unbalance using the control parameter such as the weight of the laundry W and the current of the motor 50 as shown in FIG. 7 ( 208 ).
[0084] The processes from the laundry amount detecting process 1 to the unbalance detecting process 4 correspond to a general process of reducing the unbalance in order to make the balance of the laundry W uniform before the high-speed dehydrating process of the washing machine and thus the detailed description thereof will be omitted.
[0085] Thereafter, the control unit 102 determines whether the amount of unbalance detected in the unbalance detecting process 4 is equal to or less than a predetermined first restriction value ( 210 ). If it is determined that the detected amount of unbalance is greater than the first restriction value, the rotation tub 30 is stopped and the process returns to operation 202 .
[0086] If the detected amount of unbalance is equal to or less than the first restriction value in operation 210 , the excessive vibration controlling process 5 of increasing the speed of the rotation tub 30 stepwise to pass the excessive vibration period of the water tub 20 without the vibration is performed as shown in FIGS. 7 and 8 ( 212 ).
[0087] Since the mechanical resonance point exists and a large amount of water contained in the laundry W is drained in the excessive vibration period of 160 to 300 RPM, a probability that the unbalance occurs is high. Accordingly, as shown in FIG. 8 , in the excessive vibration controlling process 5 of the present embodiment, the speed of the rotation tub 30 is not increased at once. That is, the speed of the rotation tub 30 is increased stepwise by the first step 5 - 1 to the sixth step 5 - 6 such that the amount of unbalance is not rapidly changed. Thus, the balls 61 are prevented from being rapidly moved to pass the excessive vibration period of the water tub 20 without the vibration.
[0088] During the excessive vibration controlling process 5 of increasing the speed of the rotation tub 30 stepwise, the amount of unbalance is always detected in real time and it is determined whether the amount of unbalance is equal to or less than a predetermined second restriction value ( 214 ). It is determined that the amount of unbalance is greater than the second restriction value, the rotation tub 30 is stopped and the process returns to operation 202 .
[0089] If the detected amount of unbalance is equal to or less than the second restriction value in operation 214 , the high speed dehydrating process 6 of rotating the rotation tub 30 at a high speed and draining water contained in the laundry by a centrifugal force after increasing the speed of the rotation tub 30 stepwise and passing the excessive vibration period of the water tub 20 without the vibration is performed as shown in FIGS. 7 and 8 ( 216 ).
[0090] The first restriction value and the second restriction value to determine the unbalance state of the laundry W are different from each other. The restriction values to determine the unbalance state in the processes 3 to 6 are different from each other because the unbalance degrees of the processes 3 to 6 which are performed according to the speed profile shown in FIG. 7 are different from one another.
[0091] The present embodiment will now be described in detail with reference to FIG. 10 .
[0092] FIG. 10 is a graph showing a relationship between the amount of unbalance and the speed when the excessive vibration controlling process 5 is performed in the washing machine including the balancers according to the present embodiment.
[0093] In FIG. 10 , a thin solid line represents the rotation speed (RPM) of the rotation tub 30 which is increased stepwise according to the speed profile shown in FIG. 7 , a thick solid line represents an actual amount of unbalance which occurs while the speed of the rotation tub 30 is increased stepwise according to the speed profile shown in FIG. 7 , and a dotted line represents an unbalance restriction value to determine the unbalance state while the speed of the rotation tub 30 is increased stepwise according to the speed profile shown in FIG. 7 .
[0094] As shown in FIG. 10 , the unbalance restriction values of the processes are set to be different from one another. If the speed of the rotation tub 30 is increased stepwise in the excessive vibration period of the water tub 20 of 160 RPM to 300 RPM, the amount of unbalance is increased and is then decreased as denoted by a circle of “U”. This is because a time to remove a new unbalance is allowed if a predetermined rotation speed (RPM) is maintained.
[0095] In the washing machine including the balancers according to the present embodiment, the speed of the rotation tub 30 is increased stepwise in the period (about 160 to 300 RPM) in which the excessive vibration of the water tub 20 occurs, such that the balls 61 are prevented from being rapidly moved to pass the excessive vibration period of the water tub 20 .
[0096] FIG. 11 is a graph showing a vibration value (mm) when the speed of the rotation tub 30 is increased at once in the excessive vibration period of the water tub 20 and FIG. 12 is a graph showing a vibration value (mm) when the speed of the rotation tub 30 is increased stepwise in the excessive vibration period of the water tub 20 .
[0097] As shown in FIGS. 11 and 12 , it can be seen that a maximum vibration value is 15 mm when the speed of the rotation tub 30 is increased at once in the excessive vibration period of the water tub 20 , but is 7.7 mm when the speed of the rotation tub 30 is increased stepwise in the excessive vibration period of the water tub 20 .
[0098] FIG. 13 is a graph showing a process capability obtained by repeatedly performing a vibration test in the x and y axes 30 times and analyzing the maximum vibration value when the speed of the rotation tub 30 is increased at once in the excessive vibration period of the water tub 20 under the load condition of 80 percent of laundry and FIG. 14 is a graph showing a process capability obtained by repeatedly performing a vibration test in the x and y axes 30 times and analyzing the maximum vibration value when the speed of the rotation tub 30 is increased stepwise in the excessive vibration period of the water tub 20 under the load condition of 80 percent of laundry. FIGS. 13A and 14A show the vibration in the x axis and FIGS. 13B and 14B show the vibration in the y axis.
[0099] As shown in FIGS. 13 and 14 , it can be seen that an upper limit of the vibration when the speed of the rotation tub is increased stepwise is smaller than that of the vibration when the speed of the rotation tub is increased at once in the excessive vibration period of the water tub 20 .
[0100] As described above, according to a washing machine and a method of controlling the same according to the present embodiment, since the speed of a rotation tub is increased in an excessive vibration period of a water tub in the washing machine including balancers, it is possible to pass the excessive vibration period of the water tub without the vibration.
[0101] In addition, since the unbalance state is detected in real time while the speed is increased stepwise and the speed is increased when the amount of unbalance is less than a restriction value, it is possible to prevent the rapid movement of balls and to remove the excessive vibration of the water tub with certainty.
[0102] Although an embodiment has been shown and described, it would be appreciated by those skilled in the art that changes may be made in this embodiment without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents.
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Disclosed herein is a washing machine including a balancer, which increases the speed of a rotation tub stepwise in a period in which an excessive vibration of a water tub occurs to pass the excessive vibration period without the vibration, and a method of controlling the same. The method of controlling the washing machine includes increasing the speed of the rotation tub stepwise in the period in which the excessive vibration of the water tub occurs; measuring current of a motor to detect an amount of unbalance while the speed of the rotation tub is increased stepwise; and controlling the speed of the rotation tub based on the detected amount of unbalance.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an optical lens system for taking image, and more particularly to a two-lens type optical lens system for taking image used in a mobile phone camera.
[0003] 2. Description of the Prior Art
[0004] In recent years, with the popularity of mobile phone cameras, the length of such lens systems have been reduced continuously, and the sensor of a general digital camera is none other than CCD (Charge Coupled Device) or CMOS (Complementary Metal Oxide Semiconductor). Due to advances in semiconductor manufacturing, the pixel size of sensors has been reduced from the early 7.4 um to the current 1.75 um. Therefore, there's increasing demand for miniaturization of the lens system.
[0005] In consideration of aberration correction, a conventional mobile phone's lens assembly usually consists of three lens elements, one of the typical structures is the Triplet type. However, when the length of the lens assembly is reduced from 5 mm to less than 3 mm, less space is available for the optical system, making it difficult to incorporate three lens elements into the space of the optical system. Therefore, the lens elements must become thinner, causing poor uniformity if the lens is made from plastic injection molding.
[0006] The present invention mitigates and/or obviates the afore-mentioned disadvantages.
SUMMARY OF THE INVENTION
[0007] To solve the problem of the optical system for taking image, the present invention provides an optical system for taking image, which consists of two lens elements with refractive power and an aperture stop.
[0008] A two-lens type optical system for taking image in accordance with the present invention consists of two lens elements with refractive power, from the object side to the image side:
[0009] an aperture stop;
[0010] a first lens element with positive refractive power having a convex object-side surface and a concave image-side surface, both the object-side surface and the image-side surface of the first lens element being aspheric;
[0011] a second lens element with positive refractive power having a concave object-side surface and a convex image-side surface, both the object-side surface and the image-side surface of the second lens element being asphenic.
[0012] In the present two-lens type optical lens system for taking image, the refractive power of the system is mainly provided by the first lens element with positive refractive power, and the second lens element with positive refractive power serves to balance and correct the various aberrations caused by the system. Such arrangements can effectively improve the image quality.
[0013] The first lens element provides strong positive refractive power, and the aperture stop is located close to the object side, so that the exit pupil of the optical lens system will be far away from the image plane. Therefore, the light will be projected onto the sensor with a relatively small incident angle, this is the telecentric feature of the image side, and this feature is very important to the photosensitive power of the current solid-state sensor, and can improve the photosensitivity of the sensor while reducing the probability of the occurrence of shading.
[0014] In the present two-lens type optical lens system for taking image, plastic or glass material is introduced to make lens elements. The surface of lens element is aspheric, allowing more design parameters (than spherical surfaces), so as to better reduce the aberration and the number of the lens elements, so that the total track length of the system can be reduced effectively.
[0015] In the present two-lens type optical lens system for taking image, the focal length of the first lens element is f1, the focal length of the optical lens system is f, and they satisfy the relation: f/f1>0.9.
[0016] If the value of f/f1 is smaller than the above lower limit, the refractive power of the system will be weak, the total track length of the system will be too long, and it will be difficult to suppress the incident angle of the light with respect to the sensor. Further, it will be better if f/f1 satisfies the relation:
[0000] f/f 1<1.25.
[0017] In the present two-lens type optical lens system for taking image, the focal length of the second lens element is f2, the focal length of the optical lens system is f, and they satisfy the relation:
[0000] 0< f/f 2<0.45.
[0018] The second lens element serves to balance and correct the various aberrations caused by the system. If the value of f/f2 is smaller than the above lower limit, the back focal length of the system will be too long. Further, it will be better if f/f2 satisfies the relation:
[0000] 0.05 <f/f 2<0.25.
[0019] And it will be much better if f/f1 and f/f2 satisfy the relation:
[0000] ( f/f 1)−( f/f 2)>0.35.
[0020] In the present two-lens type optical lens system for taking image, the radius of curvature of the object-side surface of the first lens element is R1, the radius of curvature of the image-side surface of the first lens element is R2, and they satisfy the relation:
[0000] 0.45 <R 1 /R 2<0.7.
[0021] If the value of R1/R2 is lower than the lower limit as stated above, it will be difficult to correct the astigmatism caused by the system. On the other hand, if the value of R1/R2 is higher than the above upper limit, it will be difficult to correct the spherical aberration caused by the system. And it will be better, if the value of R1/R2 satisfies the relation:
[0000] 0.5 <R 1 /R 2<0.65.
[0022] In the present two-lens type optical lens system for taking image, the radius of curvature of the object-side surface of the second lens element is R3, the radius of curvature of the image-side surface of the second lens element is R4, and they satisfy the relation:
[0000] 0.85 <R 3 /R 4<1.4.
[0023] the above relation is helpful for correcting high order aberrations of the system.
[0024] And it will be better if the value of R3/R4 satisfies the relation:
[0000] 0.95 <R 3 /R 4<1.35.
[0025] In the present two-lens type optical lens system for taking image, the refractive index of the first lens element is N1, and it satisfies the relation:
[0000] N1<1.59.
[0026] The above relation enables the system to obtain better image quality.
[0027] In the present two-lens type optical lens system for taking image, the Abbe number of the first lens element is V1, the Abbe number of the second lens element is V2, and they satisfy the relation:
[0000] | V 1 −V 2|<10.
[0028] The above relation can effectively correct the Coma caused by the system.
[0029] In the present two-lens type optical lens system for taking image, the radius of curvature of the object-side surface of the second lens element is R3, when it satisfies the relation: 1/R3<−0.01 mm −1 , this contributes to correct the Coma of the system.
[0030] In the present two-lens type optical lens system for taking image, the radius of curvature of the image-side surface of the second lens element is R4, when it satisfies the relation: 1/R4<−0.01 mm −1 , the absolute value of the R4 is relatively small, which contributes to reducing the back focal length of the system.
[0031] In the present two-lens type optical lens system for taking image, the tangential angle of an image-side surface of the second lens element at the position of its effective optical diameter is ANG22, and it satisfies the relation:
[0000] ANG 22<−50 deg.
[0032] The above relation can effectively reduce the incident angle of the light with respect to the sensor while improving the correction of the off axis aberration.
[0033] The tangential angle at a point on the surface of a lens is defined as the angle between the tangential plane, Plane Tan, passing through that point and a plane, Plane Norm, normal to the optical axis and passing through that point. Let T and N be the points of intersection between the optical axis and these two planes Plane Tan and Plane Norm, respectively. This tangential angle is less than 90 degree in absolute value. The sign of the tangential angle is taken to be negative if N is closer than T to the object side of the optical lens system, and positive otherwise. In the present two-lens type optical lens system for taking image, the edge thickness of the first lens element is ET1, the focal length of the two-lens type optical lens system for taking image is f, and they satisfy the relation:
[0000] ET1<0.35 mm
[0000] ET 1 /f <0.2.
[0034] The above relations facilitate correction of astigmatism of the system.
[0035] The edge thickness is; the distance between two planes normal to the lens axis, the first of which is defined as the plane passing through points on the lens object-side surface at the position of its effective optical diameter, and the second defined as the plane passing through points on the lens image-side surface at the position of its effective optical diameter.
[0036] In the present two-lens type optical lens system for taking image, an object to be photographed is imaged on an electronic sensor, a total track length of the system is TL, a maximum image height of the system is ImgH, and they satisfy the relation:
[0000] TL/ImgH< 2.2.
[0037] The above relation contributes to the miniaturization of the system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 shows an optical lens system for taking image in accordance with a first embodiment of the present invention;
[0039] FIG. 2 shows the aberration curve of the first embodiment of the present invention;
[0040] FIG. 3 shows an optical lens system for taking image in accordance with a second embodiment of the present invention;
[0041] FIG. 4 shows the aberration curve of the second embodiment of the present invention;
[0042] FIG. 5 shows an optical lens system for taking image in accordance with a third embodiment of the present invention; and
[0043] FIG. 6 shows the aberration curve of the third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0044] The present invention will be clearer from the following description when viewed together with the accompanying drawings, which show, for purpose of illustrations only, the preferred embodiment in accordance with the present invention.
[0045] Referring to FIG. 1 , which shows a two-lens type optical lens system for taking image in accordance with a first embodiment of the present invention, and FIG. 2 shows the aberration curve of the first embodiment of the present invention. The first embodiment of the present invention is a two-lens type optical lens system for taking image consisting of two lens elements with refractive power, and the two-lens type optical lens system for taking image comprises: from the object side to the image side:
[0046] A plastic first lens element 10 with positive refractive power has a convex object-side surface 11 and a concave image-side surface 12 , and both the object-side surface 11 and the image-side surface 12 of the first lens element 10 are aspheric.
[0047] A plastic second lens element 20 with positive refractive power has a concave object-side surface 21 and a convex image-side surface 22 , and both the object-side surface 21 and the image-side surface 22 of the first lens element 20 are aspheric.
[0048] An aperture stop 30 is located in front of the first lens element 10 .
[0049] A sensor cover glass 50 is located behind the second lens element 20 and has no influence on the focal length of the system.
[0050] An image plane 60 is located behind the sensor cover glass 50 .
[0051] The equation of the curve of the aspheric surfaces is expressed as follows:
[0000]
X
(
Y
)
=
(
Y
2
/
R
)
/
(
1
+
sqrt
(
1
-
(
1
+
k
)
*
(
Y
/
R
)
2
)
)
+
∑
i
(
A
i
)
*
(
Y
i
)
[0052] wherein:
[0053] X: the height of a point on the aspheric lens surface at a distance Y from the optical axis relative to the tangential plane of the aspheric surface vertex;
[0054] Y: the distance from the point on the curve of the aspheric surface to the optical axis;
[0055] k: the conic coefficient;
[0056] Ai: the aspheric surface coefficient of order i.
[0057] In the first embodiment of the present two-lens type optical lens system for taking image, the focal length of the first lens element is f1, the focal length of the second lens element is f2, the focal length of the two-lens type optical lens system for taking image is f, and they satisfy the relations:
[0000] f 1 /f 1=1.04
[0000] f/f 2=0.19
[0000] f//f 1 −f/f 2=0.85.
[0058] In the first embodiment of the present two-lens type optical lens system for taking image, the radius of curvature of the object-side surface of the first lens element is R1, the radius of curvature of the image-side surface of the first lens element is R2, the radius of curvature of the object-side surface of the second lens element is R3, the radius of curvature of the image-side surface of the second lens element is R4, and they satisfy the relations:
[0000] 1 /R 3=−0.61 mm −1
[0000] 1 /R 4=−0.78 mm −1
[0000] R 1 /R 2=0.59
[0000] R 3 /R 4=1.29.
[0059] In the first embodiment of the present two-lens type optical lens system for talking image, the refractive index of the first lens element is N1, and it satisfies the relation:
[0000] N1=1.543
[0060] In the first embodiment of the present two-lens type optical lens system for taking image, the Abbe number of the first lens element is V1, the Abbe number of the second lens element is V2, and they satisfy the relation:
[0000] | V 1 −V 2|=0
[0061] In the first embodiment of the present two-lens type optical lens system for taking image, the tangential angle of an image-side surface of the second lens element at the position of its effective optical diameter is ANG22, and ANG22=−66.8 deg.
[0062] The definition of the tangential angle is the same as before.
[0063] In the first embodiment of the present two-lens type optical lens system for taking image, the total track length of the system is TL, the maximum image height of the system is ImgH, and they satisfy the relation:
[0000] TL/ImgH= 1.94.
[0064] In the first embodiment of the present two-lens type optical lens system for taking image, the edge thickness of the first lens element is ET1, the focal length of the two-lens type optical lens system for taking image is f, and they satisfy the relations:
[0000] ET1=0.26 mm
[0000] ET 1 /f= 0.20.
[0065] The definition of the edge thickness is the same as before.
[0066] The detailed optical data of the first embodiment is shown in table 1, and the aspheric surface data is shown in table 2, wherein the units of the radius of curvature, the thickness and the focal length are expressed in mm, and HFOV is half of the maximal field of view.
[0000]
TABLE 1
(Embodiment 1)
f (focal length) = 1.32 mm, Fno = 2.85,
HFOV (half of field of view) = 32.9 deg.
Curvature
Focal
Surface #
Radius
Thickness
Material
Index
Abbe #
length
0
Object
Plano
Infinity
1
Aperture
Plano
−0.077
Stop
2
Lens 1
0.39150(ASP)
0.288
Plastic
1.543
56.5
1.27
3
0.66698(ASP)
0.185
4
Lens 2
−1.64379(ASP)
0.548
Plastic
1.543
56.5
6.85
5
−1.27619(ASP)
0.030
6
Cover
Plano
0.400
Glass
1.517
64.2
Glass
7
Plano
0.250
8
Image
Plano
[0000]
TABLE 2
Aspheric Coefficients
Surface #
2
3
4
5
K =
−4.37912E−01
−6.34894E−02
−2.90270E+02
−1.14455E+01
A4 =
3.16388E−01
1.67214E+00
−1.13309E+01
−3.54089E−01
A6 =
4.41682E+01
2.44412E+02
2.44816E+02
−1.20303E+01
A8 =
−3.69800E+02
−1.01733E+04
−5.03020E+03
8.03101E+01
A10 =
−8.32340E+02
2.08590E+05
5.08493E+04
−1.94648E+02
A12 =
4.90487E+04
−1.40944E+06
−2.63213E+05
−5.11108E+02
A14 =
−2.03976E+05
7.58510E+05
6.12515E+05
3.27313E+03
A16 =
−1.51834E+05
−4.93423E+04
4.24121E+04
−4.48455E+03
[0067] Referring to FIG. 3 , which shows a two-lens type optical lens system for taking image in accordance with a second embodiment of the present invention, and FIG. 4 shows the aberration curve of the second embodiment of the present invention. The second embodiment of the present invention is a two-lens type optical lens system for taking image consisting of two lens elements with refractive power, and the two-lens type optical lens system for taking image comprises: from the object side to the image side:
[0068] A plastic first lens element 10 with positive refractive power has a convex object-side surface 11 and a concave image-side surface 12 , and both the object-side surface 11 and the image-side surface 12 of the first lens element 10 are aspheric.
[0069] A plastic second lens element 20 with positive refractive power has a concave object-side surface 21 and a convex image-side surface 22 , and both the object-side surface 21 and the image-side surface 22 of the first lens element 20 are aspheric.
[0070] An aperture stop 30 is located in front of the first lens element 10 .
[0071] An IR cut filter 40 is located behind the second lens element 20 and has no influence on the focal length of the system.
[0072] A sensor cover glass 50 is located behind the IR cut filter 40 and has no influence on the focal length of the system.
[0073] An image plane 60 is located behind the sensor cover glass 50 .
[0074] The equation of the curves of the aspheric surfaces of the second embodiment has the same form as that of the first embodiment.
[0075] In the second embodiment of the present two-lens type optical lens system for taking image, the focal length of the first lens element is f1, the focal length of the second lens element is f2, the focal length of the two-lens type optical lens system for taking image is f, and they satisfy the relations:
[0000] f 1 /f 1=1.12
[0000] f/f 2=0.10
[0000] f//f 1 −f/f 2=1.02.
[0076] In the second embodiment of the present two-lens type optical lens system for taking image, the radius of curvature of the object-side surface of the first lens element is R1, the radius of curvature of the image-side surface of the first lens element is R2, the radius of curvature of the object-side surface of the second lens element is R3, the radius of curvature of the image-side surface of the second lens element is R4, and they satisfy the relations:
[0000] 1/ R 3=−0.53 mm −1
[0000] 1/ R 4=−0.52 mm −1
[0000] R 1 /R 2=0.62
[0000] R 3 /R 4=0.98.
[0077] In the second embodiment of the present two-lens type optical lens system for taking image, the refractive index of the first lens element is N1, and it satisfies the relation:
[0000] N1=1.543
[0078] In the second embodiment of the present two-lens type optical lens system for taking image, the Abbe number of the first lens element is V1, the Abbe number of the second lens element is V2, and they satisfy the relation:
[0000] | V 1 −V 2|=0
[0079] In the second embodiment of the present two-lens type optical lens system for taking image, the edge thickness of the first lens element is ET1, the focal length of the two-lens type optical lens system for taking image is f, and they satisfy the relations:
[0000] ET1=0.40 mm
[0000] ET1/ f =0.16.
[0080] The definition of the edge thickness is the same as before.
[0081] In the second embodiment of the present two-lens type optical lens system for taking image, the tangential angle of an image-side surface of the second lens element at the position of its effective optical diameter is ANG22, and ANG22=−56.2 deg.
[0082] The definition of the tangential angle is the same as before.
[0083] In the second embodiment of the present two-lens type optical lens system for taking image, the total track length of the two-lens type optical lens system is TL, the maximum image height of the two-lens type optical lens system is ImgH, and they satisfy the relation:
[0000] TL/ImgH= 2.14.
[0084] The detailed optical data of the second embodiment is shown in table 3, and the aspheric surface data is shown in table 4, wherein the units of the radius of curvature, the thickness and the focal length are expressed in mm, and HFOV is half of the maximal field of view.
[0000]
TABLE 3
(Embodiment 2)
f (focal length) = 2.46 mm, Fno = 2.9,
HFOV (half of field of view) = 30.0 deg.
Curvature
Focal
Surface #
Radius
Thickness
Material
Index
Abbe #
length
0
Object
Plano
Infinity
1
Aperture
0.64735(ASP)
0.477
Plastic
1.543
56.5
2.19
Stop/
Lens 1
2
1.05138(ASP)
0.308
3
Lens2
−1.88250(ASP)
0.893
Plastic
1.543
56.5
24.3
4
−1.92279(ASP)
0.100
5
IR filter
Plano
0.300
Glass
1.517
64.2
6
Plano
0.100
7
Cover
Plano
0.450
Glass
1.517
64.2
Glass
8
Plano
0.450
9
Image
Plano
[0000]
TABLE 4
Aspheric Coefficients
Surface #
2
3
4
5
K =
0.00000E+00
−6.67249E+00
0.00000E+00
1.00000E+00
A4 =
−1.33595E−01
1.30406E+00
−9.53159E−01
−8.42790E−02
A6 =
2.67131E+00
7.03352E+00
3.60696E+00
7.10030E−03
A8 =
−8.69897E+00
−1.34183E+02
−4.57290E+01
−5.81401E−01
A10 =
5.62516E+00
1.18694E+03
1.43667E+02
9.89732E−01
A12 =
3.89553E+01
−2.75284E+03
−1.99135E+02
−6.95112E−01
[0085] Referring to FIG. 5 , which shows a two-lens type optical lens system for taking image in accordance with a third embodiment of the present invention, and FIG. 6 shows the aberration curve of the third embodiment of the present invention. The third embodiment of the present invention is a two-lens type optical lens system for taking image consisting of two lens elements with refractive power, and the two-lens type optical lens system for taking image comprises: from the object side to the image side:
[0086] A plastic first lens element 10 with positive refractive power has a convex object-side surface 11 and a concave image-side surface 12 , and both the object-side surface 11 and the image-side surface 12 of the first lens element 10 are aspheric.
[0087] A plastic second lens element 20 with positive refractive power has a concave object-side surface 21 and a convex image-side surface 22 , and both the object-side surface 21 and the image-side surface 22 of the first lens element 20 are aspheric.
[0088] An aperture stop 30 is located in front of the first lens element 10 .
[0089] An IR cut filter 40 is located behind the second lens element 20 and has no influence on the focal length of the system.
[0090] A sensor cover glass 50 is located behind the IR cut filter 40 and has no influence on the focal length of the system.
[0091] An image plane 60 is located behind the sensor cover glass 50 .
[0092] The equation of the curves of the aspheric surfaces of the third embodiment has the same form as that of the first embodiment.
[0093] In the third embodiment of the present two-lens type optical lens system for taking image, the focal length of the first lens element is f1, the focal length of the second lens element is f2, the focal length of the two-lens type optical lens system for taking image is f, and they satisfy the relations:
[0000] f/f 1=1.12
[0000] f/f 2=0.16
[0000] f//f 1 −f/f 2=0.96.
[0094] In the third embodiment of the present two-lens type optical lens system for taking image, the radius of curvature of the object-side surface of the first lens element is R1, the radius of curvature of the image-side surface of the first lens element is R2, the radius of curvature of the object-side surface of the second lens element is R3, the radius of curvature of the image-side surface of the second lens element is R4, and they satisfy the relations:
[0000] 1 /R 3=−0.54 mm −1
[0000] 1 /R 4=−0.57 mm −1
[0000] R 1 /R 2=0.57
[0000] R 3 /R 4=1.05.
[0095] In the third embodiment of the present two-lens type optical lens system for taking image, the refractive index of the first lens element is N1, and it satisfies the relation:
[0000] N1=1.543
[0096] In the third embodiment of the present two-lens type optical lens system for taking image, the Abbe number of the first lens element is V1, the Abbe number of the second lens element is V2, and they satisfy the relation:
[0000] | V 1 −V 2|=0
[0097] In the third embodiment of the present two-lens type optical lens system for taking image, the edge thickness of the first lens element is ET1, the focal length of the two-lens type optical lens system for taking image is f, and they satisfy the relations:
[0000] ET1=0.34 mm
[0000] ET 1/ f= 0.15.
[0098] The definition of the edge thickness is the same as before.
[0099] In the third embodiment of the present two-lens type optical lens system for taking image, the tangential angle of an image-side surface of the second lens element at the position of its effective optical diameter is ANG22, and ANG22=−62.5 deg.
[0100] The definition of the tangential angle is the same as before.
[0101] In the third embodiment of the present two-lens type optical lens system for taking image, the total track length of the system is TL, the maximum image height of the system is ImgH, and they satisfy the relation:
[0000] TL/ImgH= 1.99.
[0102] The detailed optical data of the third embodiment is shown in table 5, and the aspheric surface data is shown in table 6, wherein the units of the radius of curvature, the thickness and the focal length are expressed in mm, and HFOV is half of the maximal field of view.
[0000]
TABLE 5
(Embodiment 3)
f (focal length) = 2.21 mm, Fno = 2.85,
HFOV (half of field of view) = 32.9 deg.
Curvature
Focal
Surface #
Radius
Thickness
Material
Index
Abbe #
length
0
Object
Plano
Infinity
1
Aperture
0.61158(ASP)
0.414
Plastic
1.543
56.5
1.98
Stop/
Lens 1
2
1.08069(ASP)
0.279
3
Lens 2
−1.85541(ASP)
0.960
Plastic
1.543
56.5
13.87
4
−1.76019(ASP)
0.100
5
IR filter
Plano
0.300
Glass
1.517
64.2
6
Plano
0.100
7
Cover
Plano
0.400
Glass
1.517
64.2
Glass
8
Plano
0.310
9
Image
Plano
[0000]
TABLE 6
Aspheric Coefficients
Surface #
2
3
4
5
K =
−5.22757E−02
−3.18655E+00
8.58498E−01
−2.72761E−02
A4 =
−3.81844E−02
8.72919E−01
−1.98682E+00
−3.52299E−02
A6 =
7.25009E+00
9.05408E+00
2.37415E+01
−3.37020E−01
A8 =
−9.48652E+01
−1.10828E+02
−3.05086E+02
3.64891E−01
A10 =
6.36165E+02
7.01340E+02
1.64481E+03
−4.50268E−01
A12 =
−1.41475E+03
3.80505E+01
−4.03874E+03
3.91933E−01
A14 =
−1.76200E+02
1.66665E−02
2.13262E+01
−3.50198E−01
[0000]
TABLE 7
Embodiment 1
Embodiment 2
Embodiment 3
f
1.32
2.46
2.21
Fno
2.85
2.90
2.85
HFOV
32.9
30.0
32.9
f/f1
1.04
1.12
1.12
f/f2
0.19
0.10
0.16
f/f1 − f/f2
0.85
1.02
0.96
1/R3
−0.61
−0.53
−0.54
1/R4
−0.78
−0.52
−0.57
R1/R2
0.59
0.62
0.57
R3/R4
1.29
0.98
1.05
N1
1.543
1.543
1.543
|V1 − V2|
0.0
0.0
0.0
ET1
0.26
0.40
0.34
ET1/f
0.20
0.16
0.15
ANG22
−66.8
−56.2
−62.5
TL/ImgH
1.94
2.14
1.99
[0103] It is to be noted that the tables 1-6 show data from the different embodiments, however, the data of the different embodiments is obtained from experiments. Therefore, any product of the same structure is deemed to be within the scope of the present invention even if it uses different data. Table 7 is the data relevant to the respective embodiments of the present invention.
[0104] While we have shown and described various embodiments in accordance with the present invention, it is clear to those skilled in the art that further embodiments may be made without departing from the scope of the present invention.
|
A two-lens type optical lens system for taking image comprises two lens elements with refractive power, from the object side: a positive first lens element with a convex object-side surface and a concave image-side surface, both the object-side surface and the image-side surface of the first lens element being aspheric; a positive second lens element with a concave object-side surface and a convex image-side surface, both the object-side surface and the image-side surface of the second lens element being aspheric, and an aperture stop located in front of the first lens element. A focal length of the first lens element is f1, a focal length of the second lens element is f2, a focal length of the optical lens system is f, a radius of curvature of the object-side surface of the second lens element is R3, and they satisfy the relations: f/f1>0.9; (f1/f1)−(f/f2)>0.35; and 1/R3<−0.01 mm −1 .
| 6
|
BACKGROUND OF THIS INVENTION
[0001] In most commercial, industrial and institutional buildings, including schools, hospitals, hotels and similar types of structures, double doors hung in frames are used. In many cases these doors are latched to a center post, called a mullion; that allows the use of single doors in double door frames. In many instances the mullion is a removable hollow core tubular shape and can be removed to allow for large loads to be passed through the doors and then reinstalled.
[0002] Specific fire codes are applied to materials used in designated areas of public buildings, including door frames, doors, mullions and related hardware. To prevent a fire from drafting, NFPA 252 fire code requires that the doors be held shut for a specified length of time during a fire. National Fire Protection Association Inc. (NFPA) 252 Fire Code was approved by the American National Standards Institute in 1995. This fire code has been nullified by improper installations of some existing mullions. The base brackets presently used to engage and secure the mullion to the floor, significantly protrude, creating an upset hazard for wheeled vehicles such as wheel chairs.
[0003] Challenges arise with securing the top and bottom ends of the mullion because of its expansion and the violent abuse it undergoes during a fire. The systems that are currently employed pose two primary safety concerns; first, installation errors that void the fire rating and second, an upset hazard due to the high profile of the base plate which appears when the mullion is removed. The mullion holding systems currently in use employ sliding wedges, springs, in an array of mechanical assemblies that must be assembled on installation, providing room for error, loss of parts and fasteners. In some instances there have been mullions that have fallen out, an injury situation being created.
[0004] This application is an improvement in the inventions disclosed in my applications Ser. No. 08/666/139 filed Jun. 19, 1996, now U.S. Pat. No. 5,765,309 and my application Ser. No. 09/062/564 filed Apr. 20, 1998, now U.S. Pat. No. 5,941,023, which by reference here are made a part of the disclosure of this application.
PRIOR ART
[0005] Various attempts have been made to overcome the problems associated with removing and reinstalling removable mullions and to make them fire rated.
[0006] U.S. Pat. No. 5,794,382 issued Apr. 18, 1998 to Prucinsky discloses a fire rated mullion using a fusible spacer mounted between two components of a group of components having overlapping joint with means for releasing clamping force when exposed to fire.
[0007] U.S. Pat. No. 5,890,319 issued Apr. 6, 1999 to Haeck et al discloses a removable mullion assembly including a spring loaded retaining bolt which locks the mullion in place. The locking mechanism is attached to the top fitting allowing the retaining bolt to be disengaged from the mullion. In the event of a fire a meltable platform within the top fitting releases a dead lock which mechanically blocks the retaining bolt from disengaging the mullion.
[0008] U.S. Pat. No. 7,000,355 issued Feb. 21, 2006 to Flory discloses a mullion arrangement for mounting a door frame including a top fitting secured to an upper frame member or header of the door frame, bottom fitting secured to the floor beneath the top fitting, and a mullion removably positioned between the top and bottom fittings. The mullion defines a cavity which carries cabling to an electric strike for regulating opening of the door.
[0009] Although these patents address the problem of providing removable mullions, they have many disadvantages as will become apparent hereinafter. Furthermore, none of them show the simple, durable, easy to use and maintain, inexpensive base plate extension for a fire rated mullion that will firmly secure the mullion to the base plate in the event of a fire; or to a low profile base plate adapted to securely receive the base plate extension during a fire; or to a mullion assembly which is fire rated comprising a mullion latch, said base plate and a removable mullion in combination with a double door frame which is friendly to the user and allows for easy and rapid removal and reinstallation of removable mullions.
OBJECTS OF THIS INVENTION
[0010] It is an object of this invention to provide a base plate extension for a fire rated removable thumb release mullion that will provide for a low profile base plate on the floor, thereby eliminating the upset hazard inherent in the use of high profile base plates, where said high profile is necessary to help secure the mullion during a fire. Further, in the event of a fire this invention permanently stops the mullion from jumping off its seat.
[0011] It is also an object of this invention to provide a low profile base plate that does not require fasteners to manually secure the mullion to the base plate.
[0012] It is further the object of this invention to provide a mullion assembly that is easy to install without nullifing the fire rating by an incorrect installation.
[0013] It is another object of this invention to provide a means of suspending the base plate extension in the core of a mullion at a predetermined distance above a receiver slot in the base plate thereby allowing for its secure engagement and alignment in the receiver slot by using the vertical characteristics of the mullion.
[0014] It is also an object of this invention to use a certified temperature rated fusible link to release the base plate extension at a predetermined temperature.
[0015] It is still further an object of this invention to use a reverse directional tensioning system to secure the base plate extension inside the mullion at a predetermined height.
[0016] It is another object of this invention to provide a fire rated mullion assembly with a removable mullion, said assembly including the means for accomplishing the forgoing objects.
SUMMARY OF THE INVENTION
[0017] These and other objects are accomplished by my invention which comprises a base plate extension having a top, a bottom and two side edges; a plate adapted to fit into the core of a mullion; means to secure said plate in the core and above the bottom end of the mullion; a low profile base plate adapted to receive and secure the bottom end of the mullion, and, having a slot or opening to receive the bottom of the base plate extension; means to cause the release of said base plate extension to fall or drop into a receiver slot or opening in the low profile base plate, thereby securing and stabilizing the position of the mullion during a fire when installed in a double door frame.
[0018] Also my invention comprises a low profile base plate adapted to receive and securely engage a removable mullion comprising a rectangular base plate adapted to secure and align a mullion, said base plate having a slot or opening adapted to receive a base plate extension which is secured in the core of the mullion and released during a fire when installed in a double door frame.
[0019] My invention also comprises a mullion assembly comprising a base plate extension; a low profile base plate; and a removable mullion having a mullion latch in combination with a door frame; said base plate extension having means for being secured in the core of the mullion comprising a reverse directional tension system and a fusible link connected to the base plate extension; said low profile base plate adapted to receive and securely engage the removable mullion, and having a slot or opening adapted to receive and secure the base plate extension when released during a fire; said mullion latch having a housing, means to secure it to the door frame header, and a latch with a lever used for installing and removing the mullion.
[0020] This invention will become apparent from the description and accompanying drawings, which illustrate preferred embodiments of this invention. A brief description of the Drawings or Figures follows.
THE FIGURES
[0021] FIG. 1 illustrates an elevation view of a double doorway viewed from the inside having swinging doors in closed position, mounted within a metal frame, with a removable mullion between doors having locking and opening mechanisms such as panic rim hardware.
[0022] FIG. 2 is an expanded elevation view from the inside of the doors, showing the latch housing secured to the top frame or header of the double door frame.
[0023] FIG. 3 is an expanded elevation view from inside of the doors, showing the base plate and its retaining protrusions for engaging the mullion in a vertical position.
[0024] FIG. 4 is an isometric drawing of a lower portion of a removable mullion with cut outs to better illustrate the reverse directional tensioning system, the fusible link, and the alignment of the base plate extension with the receiver slot in the base plate.
[0025] FIG. 5 is a side elevation illustrating a lower portion of a removable mullion installed on a base plate with the protrusions securing the mullion in tight alignment. A receiver slot has been provided in the base plate that will accept the base plate extension. The base plate extension is attached to the bottom of a fusible link that is suspended from two reverse arched springs,(i.e. reverse directional tensioning system), secured back to back and tension held within the mullion between its opposite inside troughs.
[0026] FIG. 6 is a plan elevation of the base plate illustrating the holes provided for fasteners to secure the base plate to the floor. Further, illustrated are the contact points around the perimeter that engage the mullion. This illustration clearly shows the diagonally intersecting receiver slots for the base plate extension.
[0027] FIG. 7 is a side elevation illustrating a removable mullion mounted on a base plate, with the base plate extension engaged inside the receiver slot, which is provided within the base plate. The base plate extension has been released at a set temperature caused by a fire. The engagement between the released base plate extension within the receiver slot secures the mullion. The base plate protrusions have now been increased to include the length of the base plate extension, thus it is not possible for the mullion to disengage from the base plate.
A BRIEF DESCRIPTION OF THE INVENTION
[0028] The following Brief Description of the Invention is best understood with reference to FIG. 4 .
[0029] In the event of a fire, this system will increase the length of engagement between the base plate, 1 , and the mullion, 2 , making it impossible for the mullion, 2 , to disengage from the base plate, 1 .
[0030] In the event of a fire, the base plate extension, la, that is hung from a reversed directional tensioning system, comprising a pair of reverse arched springs, 10 , that are secured to the top end of a certified fusible link, 9 , the base plate extension, la, is secured to the bottom end of the certified fusible link, 9 . When a specific temperature is reached during a fire, the certified fusible link, 9 , will separate allowing the base plate extension, la, to drop and engage with the receiver slot in the base plate, 1 , securing the mullion, 2 , permanently in place.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Referring to FIGS. 1 through 7 :
[0032] FIG. 1 illustrates an elevation view of a double doorway viewed from the inside, having doors, 13 , mounted within a door frame, with header, 4 , door frame jams, 5 , doors, 13 , fitted with rim panic hardware, 6 , and showing the removable mullion, 2 , between the doors fitted onto a base plate, 1 , over its protrusions, 7 , and locked in place at the top by the mullion latch and housing, 3 , therefore securing the mullion, 2 , at the top and bottom of the door frame. The latch housing, 3 , is a thumb release device as described in my U.S. Pat. No. 5,765,309, which allows for easy removal of a mullion without tools.
[0033] FIG. 2 illustrates an expanded elevation view from the inside of the doors, 13 , showing the mullion latch housing, 3 , secured to the doorframe header, 4 , with bolts, 12 , the opening for the thumb lever in the rear leg of the housing, 15 , that allows the thumb lever, 16 , to protrude to the outside, so it can be depressed to release the mullion, 2 . There is a provision in the latch housing, 3 , that allows for the mullion, 2 , to expand in its length during a fire. The opening of the housing that allows for expansion maybe left as unfinished or may be covered by a mullion replica, not shown, to give the impression of a mullion. This cover has no structural purpose; therefore it can be made of any material that will disintegrate in a fire. Alternatively, a metal insert fitting on the outside of the mullion may be employed, thereby allowing the expanding mullion to telescope into the inside of the metal insert during a fire.
[0034] FIG. 3 illustrates an expanded elevation view from inside the doors, 13 , showing the base plate, 1 , and the retaining protrusions, 7 . During normal operation of the removable mullion, 2 , the protrusions, 7 , which protrude approximately 3 / 8 ″ providing adequate engagement to hold the mullion, 2 . In the event of a fire, the mullion, 2 , may be exposed to severe drafts or wind gusts which could pull the mullion, 2 , off the seat or protrusions, 7 , causing the doors to open. The base plate, 1 , is secured to the floor with lag bolts and shields or comparable means (not shown in FIG. 3 ).
[0035] FIG. 4 is an isometric drawing with cut outs to better illustrate the reverse arched springs, 10 , the certified fusible link, 9 , and the alignment of the base plate extension, 1 a, with the base plate receiver slot, 8 , in the base plate, 1 .
[0036] FIG. 5 illustrates a side elevation view of the mullion, 2 , mounted on the base plate, 1 , with the protrusions, 7 , inside the bottom of the mullion, 2 . The base plate, 1 , has been provided with two diagonal receiver slots, 8 a , to prevent the installer from making the mistake of reversing it, therefore the base plate extension, 1 a , will line up with the receiver slot, 8 , even if the base plate extension, 1 a , itself is reversed in its diagonal mounting in the mullion, 2 , the base plate extension, 1 a , which is made to fit diagonally inside the mullion, 2 , and free enough as not to impede its travel down the mullion, 2 , in the event of a fire, the length of the base plate extension, 1 a , prevents the base plate extension, 1 a , from wobbling inside the mullion, 2 . The base plate extension, 1 a is secured to one end of a certified fusible link, 9 , which has a set melting point; the other end of this certified fusible link is secured to a pair of reverse arched springs, 10 , coupled back to back and tensioned inside the mullion, 2 , and between the two opposite troughs, 14 , FIG. 4 . With the weight of the base plate extension, 1 a , pulling down on the reverse arched springs, 10 , the load is being applied to the arch of the lower spring, the ends of which are tensioned into the sides of the mullion, 2 , the more pressure that is applied, the more the spring will tension; the reverse would apply to the top spring.
[0037] FIG. 6 is a plan elevation of the base plate, 1 , illustrating the diagonal receiver slots, 8 a , for the base plate extension, 1 a , also shown are the bolt holes, 11 , used to secure the base plate, 1 , to the floor. The contact points on protrusions, 7 , are clearly visible.
[0038] FIG. 7 illustrates the base plate extension, 1 a , in the dropped position where it is engaged with the base plate, 1 , via the receiver slot, 8 , Now the base plate, 1 , and the base plate extension, 1 a , are unified as one part, and engage the mullion, 2 , at, 1 b , by approximately 3″ making the combination totally secure, even if the mullion, 2 , was to rise above the base plate protrusion, 7 , the mullion, 2 , is still held secure by the engagement portion, 1 b , of the base plate extension, 1 a . The mullion, 2 , has now become a non removable mullion.
EXAMPLE
[0039] The fire rated mullion is simply installed within a double door frame as shown in FIG. 1 . The latch housing, 3 , is secured by fastening means, to the door frame header, 4 , and is centered at the point where the double doors meet. The base plate, 1 , is fastened to the floor and is also centered to where the double doors meet, and is aligned flush with the doors. The mullion, 2 , with the base plate extension, 1 a , which is firmly secured inside the core of the mullion, approximately two feet above the floor by using reverse arched springs, 10 , thereby holding the base plate extension, 1 a , in place during the handling and cutting the mullion, 2 , to length,. The mullion, 2 , is inserted over the bottom of the rear leg of housing, 17 , indicated by hidden line in FIG. 2 , of the latch housing, 3 . The bottom end of the mullion, 2 , is guided over the protrusions, 7 , FIG. 3 , on the base plate, 1 . Now the top of the mullion, 2 , is simply pushed ahead into place and is locked in by the latch within the housing, 3 .
[0040] For removal of the mullion, 2 , the thumb latch lever, 16 , is depressed and the mullion is pulled back and lifted out, the base plate extension, 1 a , FIG. 4 , is not disturbed during normal operation of the mullion, 2 .
[0041] During a fire the base plate extension, 1 a , which is secured to the reverse arched springs, 10 , via a certified fusible link, 9 , FIGS. 4 and 5 ; when this link reaches a specified temperature it separates allowing the base plate extension, 1 a , to fall and engage within the diagonal slot in the base plate, 1 , FIG. 7 ; thereby increasing the engagement the base plate extension and the base plate from ⅜ of an inch to 3 inches, during a fire, thus the mullion, 2 , is now unable to become disengaged. The low profile base plate, 1 , FIG. 5 , during normal operation is ⅝ inches off the floor which includes the protrusions, 7 . This height avoids conditions for upsetting wheel chairs, avoids tripping hazard and provides lower undercarriage clearance for moving machinery through the widened doorway opening.
Modifications
[0042] Although the foregoing description, discloses the use of a reverse directional tension system such as reversed arched springs mounted back to back and tension held inside the core of a mullion at a given height from the bottom end of the mullion, various means other than such inversed tension means maybe employed, such as adhesives, threaded fasteners, and the like. The holding devices that hold the certified fusible link and the reversed arched springs together maybe bolted, riveted, fused, crimped, or molded. I have found that positioning of the base plate extension in the core of the mullion by securing it about two feet from the bottom end of the mullion is satisfactory for performance to meet the NFPA 252 Fire Code, however other positions may be employed. All that is required in accordance with my invention is that the base plate extension be secured in place in the core of the mullion so that the mullion may be handled and worked on, such as during installation, and remain in ready position high enough in the core to drop into the base plate receiver opening when the fusible link is melted, providing the means for releasing the base plate extension during a fire so that it may be securely engaged in the receiver opening in the base plate thereby securing the mullion when in the upright position.
[0043] The means for releasing the base plate extension consists of a material that will bind together the reverse arched springs to the base plate extension and melt by the heat of a fire, thereby causing the base plate extension to drop into the receiver slot. Certified fusible link material is used in accordance with my invention for fire rated installations; that is, a fusible link certified to melt at a given temperature during a fire. For example, certified fusible link material is composed of two metal strips, such as tin bonded by solder, epoxy resin, and the like which melt at a predetermined temperature. Alternatively, other materials such as plastic, nylon and the like may be utilized provided they have the predetermined melting temperature characteristics. Thus, in accordance with my invention the only requirement of the certified fusible link is that it binds the reversed directional tensioning system to the base plate extension and that it melts at a predetermined temperature.
[0044] The base plate extension can vary in shape and size and thickness, the preferred parameters are that the width from side to side is just loose enough to permit the base plate extension to travel freely and yet be guided into the receiver slot in the base plate during a fire. The weight and thickness should be heavy enough so as not to bend or distort if the mullion was to jump off its seat on the base plate during a fire. The height from top to bottom of the base plate extension should be sufficient to prevent the base plate extension from wobbling during decent into the receiving slot or opening in the base plate during a fire.
[0000] The low profile base plate receiver slot in the preferred embodiment is shown as, 8 , in FIG. 4 and in FIG. 6 , however, variations in design are also applicable in my invention. For example, instead of raised protrusions, jut outs, projections and the like may be designed to provide the receiver slots for securing the base plate extension when dropped in a fire. Furthermore, the receiver slots may be provided in a flat surfaced base plate and all that is required in accordance with my invention is to maintain a low profile base plate of about ⅝ inch thickness in order to avoid a hazardous condition when objects are moved through the widened open doors. The receiver slots or openings may be varied from the diagonal slots shown in FIGS. 4 and 6 . For example, round holes, key holes and various other designs of apertures, depressions, grooves or notches may be employed just as long as the bottom edge of the base plate extension is designed to fit into the receiver slots to secure and stabilize the position of the mullion during a fire when installed in a double door frame. Even though a flat plate is described in the above description, any shape that will hold the mullion in direct alignment to prevent torsional twisting may be employed.
[0045] The mullion replica insert or sleeve, may be in one mode, be made of any material that is friable, shatter able or crush able under the pressure generated when the mullion expands, thereby allowing space for the expansion and maintaining the integrity of the mullion. For example, glass, ceramic, foamed or sintered metal and other substances that can be shaped to replicate the mullion may be used. In another mode, the mullion replica insert or sleeve, may be made of materials that are fusible and displaced during a fire, such as plastics, composite of fusible materials and the like, thereby providing space for expansion of the mullion during a fire. The mullion replica sleeve is ornamental, not necessary for a fire rating and therefore not a utility part.
[0046] The mullion assembly in the preferred mode of my invention is composed of parts made of steel which is commonly used in most installations of double door mullion passage ways. Other metals and various grades of steel, such as stainless steel or even titanium and the like that have similar heat resistant properties during a fire may be employed. In the foregoing description I have described a removable mullion with a thumb latch release, however, other mechanism for removing the mullion may be used in combination with the base plate extension and/or low profile base plate of my invention.
[0047] I have exemplified my invention using preferred embodiments, it is to be understood that departure may be made there from within the scope of my invention, which is not to be limited to the details disclosed herein, but is to be accorded the full scope of the appended claims so as to embrace all equivalents.
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This invention relates to a base plate extension for a fire rated mullion that will firmly secure the base of the mullion in the event of a fire; to a low profile base plate; and, to a mullion assembly comprising a low profile base plate, a mullion latch, and a removable mullion in combination with a double door frame. A removable fire rated mullion is used in conjunction with double door openings to provide a securing point for rim panic bars mounted on doors. For a fire rating to be recognized it must comply with the standard, national Fire Protection Association Inc. (NFPA) 252 Fire Code. The (NFPA) 252 Fire Code was approved by the American National Standards Institute in 1995.
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FIELD OF THE INVENTION
The invention relates to inflatable well bore packers and more particularly to inflatable well bore packer systems for use in large diameter casing in underwater or subsea operations.
BACKGROUND OF THE INVENTION
Subsea completions are occurring at ever increasing depths and are utilizing larger diameter casings. One of the problems encountered in subsea completions are subterranean gas and/or water zones which complicate the cementing process for a casing, such gas or water fluids can cause channeling to occur when the annulus about a well casing is cemented. It is, of course, important to that the cement seal off the annulus and to prevent fluid intrusion while the cement sets up in the annulus. One solution is to use an inflatable packer. However, with large diameter casing there is usually a restricted bore. It is difficult to cement the casing and to actuate an inflatable packer on a casing because of both the bore size of the casing and the restricted bore size of some of the wellheads.
THE PRESENT INVENTION
The present invention is for large diameter, subsea well operations where a casing and attached wellhead present a restricted bore opening and it is desired to set the casing where the casing traverses one or more locations which introduce intruding fluids to the well bore.
The operations involve setting a first conductor well head and a conductor pipe in the earth formations below the subsea floor. Next, an integrated assembly consisting of (1) a tubular casing and attached casing wellhead and (2) a tubing string within the casing where the tubing string extends from a running tool to float shoes at the lower end of the casing and extends from the running tool to the drilling rig. The running tool is attached to the casing wellhead. In the casing, at a location selected to be above the location having intrusive fluids, is an inflatable packer. The bore of the inflatable packer is fitted with a tubular drillable insert for providing a smaller bore in the packer. The effective bore in the packer has a bore diameter less than the diameter of the bore of the attached casing wellhead. The tubing or pipe string has an attached tubular seal member located along its length which is sealingly received in the bore of the drillable insert. The seal member has a normally closed valve which isolates the inflatable packer from the bore of the seal member when primary cement slurry is pumped down the tubing string. With the tubing string extending downwardly to the float shoes in the lower end of the casing, the mud in the annulus between the casing and the tubing causes the cement slurry to fill the annulus between the casing and borehole to the wellhead. Upon filling the annulus with primary cement slurry, a packer inflation cement slurry is pumped down the tubing string behind a cementing dart. When the dart reaches the seal member, it opens the normally closed valve to channel inflation cement to the inflatable packer and inflate the packer cement on the inflatable packer. The inflatable packer then effectively isolates the annulus above the intrusion location so that the primary cement above the packer element can set up properly to support the casing.
Before the cement slurry sets up in the annulus, and also inside the tubing workings, the running tool is disengaged from the casing wellhead and the seal member can be retrieved through the restricted bore of the wellhead. Thereafter, the drillable insert can be removed by a underreaming operation. Of course, if the next borehole to be drilled has a diameter smaller than the bore of drillable insert, the insert can be left intact or in place. In either case the inflatable packer can be safely and reliably inflated without undue use of cement in the casing.
DESCRIPTION OF THE DRAWINGS
FIGS. 1, 2, and 3 are views of the invention illustrated in a subsea wellbore during primary cementing, just prior to packer inflation, and after packer inflation.
FIG. 4 is a view in partial cross-section of the inflatable packer of the present invention and;
FIG. 5 is an enlarged view in cross-section through a part of the inflatable packer of the present invention.
DESCRIPTION OF THE INVENTION
In one type of underwater completion, a conductor pipe is attached to a conductor wellhead and is driven into the ocean floor. The conductor pipe is typically 200 to 300 feet in length. For example, in 3000 feet of water, a 36" conductor wellhead with an attached conductor pipe can be utilized as a foundation in the earth formations below the sea floor for receiving a casing where the casing is subsequently cemented in place. The casing is typically 2000 to 3000 feet in length. In this instance, after the conductor pipe and the wellhead are installed, a well bore is drilled for the length of casing desired thru the 36" pipe to the desired depth below the bottom of the conductor pipe.
As shown in FIG. 1, a first conductor wellhead 10 with an attached conductor pipe 11 are located in a subsea template location on an ocean floor 14. A well bore 15 for the casing is then drilled thru the 36" pipe to a desired depth 17 in a conventional manner. In the process, it is not uncommon for the well bore 15 to traverse subterranean fluid flow zones 18 which contain water and/or gas which can intrude into the well bore and adversely affect the cementing of the casing.
After drilling the well bore 15, it is desired to cement a tubular, large diameter, casing 19 in place in the well bore 15 with a good cement job despite the fluid input to the annulus 20 between the casing 19 and the wellbore 15. The casing can be 26" in diameter. The casing 19 is attached to a second casing wellhead 12. The second casing wellhead 12 is releaseably coupled to a string of tubing by a running tool 27.
For ease of description, the entire assembly in its assembled position for operation, as shown in FIG. 1, will be described first.
Along the string of casing 19, in a location above the fluid input zone 18, is an external inflatable packer 30. At the lower end of the casing are float shoes and float collar or valves 32, 33. The second casing wellhead 12 sets in the first conductor wellhead 10, but has a flow passage 35 (shown by the dark line) which extends between the surfaces of the wellheads from the annulus 20 to the ocean floor 14 to permit fluid flow from the annulus 20 into the ocean. In some well heads, there is a flow passage with a remote controlled valve in the conductor wellhead.
The structure of the inflatable packer is illustrated in more detail in FIGS. 4 and 5. The packer 30 has a tubular inflatable packer element 40 which is secured to upper and lower heads 42, 43 where the heads are coupled to the casing 19. In the upper head 42 is a flow passage 45 with valve members 46 where the flow passage 45 extends between the interior of the packer element 40 and an annular recess 50 in the interior bore of the head 42. The valves 46 include a shear valve, a check valve and a limit valve (For example, see U.S. Pat. No. 4,655,286 or 4,402,517) which operate to open the flow passage, prevent back pressure flow, and shut off the flow at the desired inflation pressure. An inflation cement when pumped through the flow passage 45 will inflate the packer element into sealing engagement with the wall of the wellbore. An inflation packer typically can be 20 to 40 feet in length depending upon the bore size.
Disposed in the casing 19 and coextensively extended with respect to the upper head 42 is an tubular isolation sleeve or drillable insert 52. The sleeve or insert 52 is constructed of a drillable material such as aluminum and is threadedly and sealably attached to the upper head 42. The sleeve 52 has radial ports 54 extending between the annular recess 50 and the bore 56 of the isolation sleeve 52. The bore 56 of the sleeve 52 is smaller in diameter than the diameter of the bore 60 in the wellhead 12 (see FIG. 2).
The tubing string 25 is attached to the running tool 27 and has an isolation seal member 65 disposed along its length so that the isolation seal member is disposed in the bore 56 of the isolation sleeve 52. The isolation seal member 65 has an outer annular recess 67 located between sealing elements 68, 69. The annular recess 67 is connected to the bore 66 of the isolation seal member 65 for fluid flow by means of radial ports 70. In the bore 66 of the isolation seal member is tubular sleeve valve member 72 which has sealing elements 73, 74 located above and below the flow ports 70. The valve member 72 has a shear ring 76 disposed in grooves in the valve member 72 and the seal member 65. The shear ring 76 releasably retains the valve member 72 in a closed position over the ports 70. Below the valve member 72 the tubing has an interior stop shoulder or flange 80 which limits downward movement of the valve member 72 when it is shifted to an open position. As shown in the drawings, the isolation sleeve 52 has longitudinally extending bypass passages 78 which define a fluid equalization bypass about the seal member 65. If desired, the bypass can be in the body of the seal member 65.
With the above apparatus, the process involves assembling the casing 19 and tubing 25 in the positions shown in FIG. 1 and lowering the assembly with the running tool 27 and the tubing string until the casing 19 and the casing wellhead 12 are lowered into the conductor wellhead 10. The inflation ports in the inflatable packer, in the isolation member and in the seal member are prealigned but closed off by the sleeve valve member. At this time the inflatable packer 30 is disposed above the fluid zone 18 and is prevented from actuation by the closed sleeve member 72. The isolation seal member 65 seals off the access port 70 to the packer and the string of tubing (51/2" diameter) extends to just above the float shoes 32, 33.
As shown in FIG. 2, the primary cement job is commenced and cement slurry 84 is introduced through the string of tubing 25 (slurry 84A) to the wellbore annulus 20 between the casing and the wellbore. The flow channel 35 between the wellheads 10 & 12 permit liquid (mud) to exit to the ocean and it can be determined when the cement slurry 84A begins to exit the flow channel 35. At this time, a packer inflation cement 85 is introduced behind a cementing dart 86 to the string of tubing (see FIG. 2). The inflation cement is pumped through the tubing 25 until the cementing dart 86 lands on the sleeve valve 72. Continued pressure on the inflation cement 85 causes the sleeve valve 72 to shift to an open position by shearing the shear ring 76 and stop below the isolation seal member 65 at the stop shoulder or flange 80. The packer element 40 then is inflated as shown in FIG. 3 by the inflation cement under pressure. This is accomplished before the primary cement 84A above the packer element is set up in the annulus 20 so that fluids from the zone 18 below the packer 30 are shut off with respect to the annulus 20 by the inflatable packer.
After the packer element 40 is inflated, the string of tubing 25 can be removed from the casing 19 by lifting upward. The isolation seal member 65 is sized to pass through the restricted bore 60 of the wellhead 12.
Subsequently, the isolation sleeve 52 can be removed with an underreamer. Or, if the casing collars of the next casing size are smaller than the bore, then the sleeve 52 does not need to be underreamed.
Thus, with the present invention, an inflatable packer in a casing string attached to a wellhead can be inflated even though the bore of the casing is larger than the bore of the wellhead.
It will be apparent to those skilled in the art that various changes may be made in the invention without departing from the spirit and scope thereof and therefore the invention is not limited by that which is disclosed in the drawings and specifications but only as indicated in the appended claims.
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A subsea packer system for large diameter casings where an inflatable liner is connected in a string of casing and has an inner tubular drillable insert member with a longitudinal bypass passage. A string of tubing with a releasable running tool is connected to a casing well head on the casing for transport into a well bore and has an isolation seal member for closing off inflation ports which extend through the insert member to the inflatable packer. The bore of the insert member is sized to a bore diameter less than the bore diameter of the casing well head and is less than the diameter of the casing.
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PRIOR APPLICATION DATA
[0001] The present application is a continuation of prior U.S. application Ser. No. 11/905,677, filed on Oct. 3, 2007, and entitled “METHOD FOR ACTIVATING AN IMAGE COLLECTING PROCESS”, which in turn is a continuation of prior U.S. application Ser. No. 10/130,326, filed on May 15, 2002, and entitled “METHOD FOR ACTIVATING AN IMAGE COLLECTING PROCESS”, which in turn is a national phase application of International Application Serial No. PCT/IL00/00752, entitled “METHOD FOR ACTIVATING AN IMAGE COLLECTING PROCESS”, filed on Nov. 15, 2000, which in turn claims priority from Israel application 132944, filed on Nov. 15, 1999, all of which are hereby incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] The present invention generally relates to a method for the activation of an image collecting process. More specifically, the method of the present invention can be applied to an image collecting process meant for imaging the inside of body lumens.
BACKGROUND OF THE INVENTION
[0003] Single chip imaging devices such as charge coupled devices (CCD) and CMOS type image sensors can operate using small power sources and relatively little energy. Such imaging devices are implemented in applications as diverse as star tracking applications and imaging the inside of the gastrointestinal tract.
[0004] For example, U.S. Pat. No. 5,604,531, assigned to the common assignee of the present invention, describes a swallowable capsule for imaging the full length of the gastrointestinal tract. The swallowable capsule includes a camera system, an optical system for imaging an area of interest onto the camera system and a transmitter which transmits the video output of the camera system.
[0005] In some instances the imaging devices are inaccessible to an operator at the appropriate time for activation, such as for reasons of sterility, and must be activated by remote control such as by IR or radio.
[0006] A method for activating a battery, though not a battery of an imaging device, is exemplified in PED Incs swallowable temperature pill. PED Inc. advertises a swallowable temperature pill for tracking core body temperature. The temperature pill is powered by a silver oxide battery. The battery is kept turned off during storage by a small magnet that is taped to the pill package and is activated by removing this magnet.
SUMMARY OF THE INVENTION
[0007] The present invention relates to a method for activating an image collecting process, comprising the step of releasing the power source of a component essential to the image collecting process from an inhibition imposed by an external magnet. The method enables facile and sterile activation of the image collecting process, since activation of the process does not require directly handling any component participating in the process and does not require a third party, such as a remote control operator.
[0008] An image collecting process is a process in which images are obtained and components essential to the image collecting process are those power source driven components whose operation is necessary for obtaining an image. Components essential to the image collecting process may be an imaging device, such as low energy imaging devices, i.e., a CCD camera or a CMOS type image sensor, a light source for illuminating the target to be imaged, etc.
[0009] The term power source of a component essential to the image collecting process includes a motor or an engine which utilize a power source for operating the component.
[0010] The term “external magnet” in the present invention refers to a magnet positioned relatively to the component or components essential to the image collecting process, such that it is capable of inhibiting the essential component or components power source.
[0011] In an embodiment of the invention the image collecting process is designed to image the insides of a body lumen. The essential components can be a part of or attached to a medical device that is inserted into the body lumen, such as a needle, stent, endoscope or a swallowable capsule. The external magnet is part of or attached to the medical device package and is removed once the device package is removed.
[0012] The present invention further relates to a packaging suitable for storing therein an imaging system, said package comprising a magnet. The imaging system comprises components essential to an image collecting process, said components operable in accordance with the invention.
[0013] The present invention still further relates to a method for imaging a body lumen comprising the steps of:
[0014] a) providing an imaging system inserted in a balancing cup, said imaging system comprising a camera system having video output; an optical system for imaging an area of interest onto said camera system; a transmitter which transmits the video output of said camera system;
[0015] b) activating within the imaging system an image collecting process;
[0016] c) releasing the imaging system from the balance cup; and
[0017] d) inserting the imaging system into a body lumen.
[0018] The imaging system may also comprise other components such as a light source for illuminating an area of interest, a reception system which receives the transmitted video output, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The present invention will be understood and appreciated more fully from the following detailed description taken in conjunction with the appended drawings in which:
[0020] FIG. 1 is a schematic illustration of a prior art swallowable capsule comprising an imaging device;
[0021] FIG. 2 is a schematic illustration of an imaging device in a package in accordance with an embodiment of the invention; and
[0022] FIG. 3 is a side view of the imaging device and package illustrated in FIG. 2 .
[0023] FIG. 4 is a block diagram of the method of the invention according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The method of the present invention comprises the step of releasing the power source of any component essential to an image collecting process, of an inhibition imposed by an external magnet.
[0025] The essential components are those power source driven components whose operation is necessary for obtaining images. Essential components for obtaining images are, for example, an imaging device or an illumination source (depending on the requirements and sensitivity of the imaging device). The imaging device can be any image sensor suitable for use in the method of the present invention, such as CCD cameras or CMOS image sensors. The energy for the imaging device is usually supplied through a low energy motor comprising either an electrical or permanent magnet.
[0026] The external magnet can be either more powerful than the essential component motor magnet or aligned with the essential component motor magnet such as to neutralize its magnetic field. Thus, proximity of the external magnet to the essential component power source or motor acts to inhibit the activation of the image collecting process since components essential for the image collecting process are not operative.
[0027] The external magnet may be distanced from the essential component power source or motor, so as to enable the essential component operation, directly by an operator or by mechanical or other means, suitable for distancing the external magnet from the essential component power source or motor.
[0028] In one embodiment of the invention an imaging device is attached to or is a part of a medical device that is suitable for imaging the inside of body lumens, such as blood vessels, the gastrointestinal tract, etc. The medical device may be a stent, needle, endoscope or swallowable capsule, or any other device suitable for being inserted into body lumens.
[0029] Reference is now made to FIG. 1 which shows a schematic illustration of a prior art swallowable capsule comprising an imaging device. Such a swallowable capsule is described in U.S. Pat. No. 5,604,531. U.S. Pat. No. 5,604,531, which is assigned to the common assignees of the present invention, is hereby incorporated by reference.
[0030] Swallowable capsule 10 typically comprises a viewing unit 11 and a unit 12 housing the electrical elements of the capsule. The viewing unit 11 contains an imaging system which includes a light source 18 , a viewing window 14 through which the light illuminates the inner portions of the digestive system, the image collector component of an imaging device 16 , such as a charge coupled device (CCD) camera, which detects the images, an optical system (not shown) which focuses the images onto the image collector component of the imaging device 16 , and means for transmitting the video signal of the imaging device. The imaging system may also include a reception system which is in communication with the imaging device and which receives the transmitted video output.
[0031] The unit 12 typically includes the electronics and power source for producing a video signal from the output of the CCD device and a power source, such as a battery, which provides power to the entirety of electrical elements of the capsule.
[0032] Reference is now made to FIGS. 2 and 3 which are schematic overview and side views of a swallowable capsule 20 in a package 22 in accordance with an embodiment of the invention. Capsule 20 is similar to the capsule described in FIG. 1 . The viewing unit of the capsule 20 is inserted in a white balance cup 26 , which in turn is attached to a holder 28 , for sterile handling of the capsule 20 . Capsule 20 , holder 28 and balance cup 26 are encased in package 22 which comprises a magnet 24 . The package 22 also includes a base 23 ( FIG. 3 ) and a transparent sterile upper plastic cover 21 ( FIG. 3 ). The magnet 24 is positioned in alignment with the encased capsule 20 such that the magnet 24 inhibits the imaging device power source or inhibits the battery which provides power to the entirety of electrical elements of the capsule.
[0033] The magnet 24 may be ring shaped or curved (as illustrated in FIG. 2 ) so that no specific directionality of the capsule, in relation to the magnet, is required.
[0034] The imaging system in capsule 20 , while the capsule 20 is still in the package 22 , is inactive due to the proximity of the magnet 24 . The imaging device and/or other power source driven components of the capsule 20 are activated once the capsule is distanced from the magnet 24 , namely by removing the capsule 20 from the package 22 . The capsule 20 may be removed from the package 22 by peeling off either base 23 or cover 21 in the direction shown by arrow 25 and extracting the holder 28 , balance cup 26 and capsule 20 inserted therein.
[0035] The package 22 may be made of any material suitable for storing capsule 20 . For example, package 22 may be a blister type package in which cover 21 is made of a firm but flexible plastic and base 23 is a foil of material which can be ruptured by pressure applied by a user. Capsule 20 is released from the package 22 by exerting pressure on it, through the cover 21 in the direction of the base 23 of the package 22 , until the base 23 is ruptured, releasing the holder 28 , balance cup 26 and capsule 20 inserted therein.
[0036] Once the capsule 20 is released from package 22 it is distanced from magnet 24 and the imaging device and/or other components essential for the imaging collecting process in capsule 20 are activated and the imaging system begins capturing images. Having the viewing unit of the capsule 20 inserted in a white balance cup 26 , ensures that the first images captured and transmitted are white, thus enabling automatic white balance. The capsule 20 can be snapped out of the balance cup 26 to be swallowed by the patient.
[0037] In another embodiment the balance cup is marked on its inner wall, which is the wall being imaged once the image collecting process initiates. The image collecting process is operated for a predetermined initial period, prior to being released from the balance cup, during which identification of the mark is preformed. The image collecting process will be allowed to proceed only if identification of the mark is positive.
[0038] The mark may be a company logo or any other emblem or string of characters. The mark may be used, inter alia, to ensure that all parts of the imaging system are compatible, for example, that the capsule and its imaging device are compatible with the reception system and its software.
[0039] This point is demonstrated by the block diagram presented in FIG. 4 .
[0040] Inhibition of the power source of any component essential to the image collecting process is removed ( 32 ) and the image collecting process initiates ( 34 ). As discussed above, the first images collected will be images of the balance cup inner walls and of any mark on the balance cup inner wall. This initial data received from the imaging device is perceived by a reception system which is in communication with the imaging device and a process of identification of the mark ( 36 ) is initiated. The following factors, for example, might require adjustment for accurate identification of the mark:
[0041] a) The light conditions might vary between different capsules due to environment light and due to differences in the electronic components of the capsule (such as the light source and sensor);
[0042] b) The capsule and balance cup are not necessarily aligned, which will cause the image of the mark to appear in a different rotation angle each time;
[0043] c) The distance from the actual image is not accurate which results in different sizes of the object in the image; and
[0044] d) The image of the mark needs to be compared to a reference image and similarity needs to be confirmed.
[0045] Various algorithms may be executed to ensure accurate identification of the mark. For example, the following algorithms are executed in order to overcome the above:
[0046] Light correction ( 36 a ) is performed using an algorithm similar to AGC (Automatic Gain Control). This algorithm measures some statistical parameters of the input image. (The image is divided into 8×8 blocks and the average intensity is calculated. From this array average intensity and minimum and maximum block intensity are calculated.) Next, the brightness and contrast of the image are changed in order to bring the statistical parameters to a reference value.
[0047] In order to correct rotation ( 36 b ) the image is converted from Cartesic coordination into polaric coordination (from X,Y plane into R Theta plane), where R=SQRT (X*X+Y*Y) and Theta=ATAN(X/Y).
[0048] After the conversion of the image into R, Theta plane, the magnification is corrected ( 36 c ) by applying a LOG function to the image. This function converts magnification, which is actually multiplication by a factor, into a bias/shift difference.
[0049] The identification of the mark is done by an image identification process ( 36 d ) in which the cross correlation function between a reference image and the input image is calculated and the maximum value of this cross correlation function is calculated. This maximum value is compared to a threshold. If it is higher than the threshold then the conclusion is that the images are similar.
[0050] If the result is that the images are similar (identification is positive), the image collecting process is allowed to proceed ( 35 ). If the result is that the images are not similar (identification is negative), the image collecting process is terminated ( 37 ).
[0051] Thus, the system will operate initially, for a predetermined time or to collect a predetermined number of frames, but the image collecting process will be allowed to continue further than the initial operation only if identification of the mark is positive. This mode of operation can be utilized to ensure that the system will only operate when all its components are the original components. For example, an original reception system that is used with a swallowable capsule from a different make (that does not have a marked balance cup) will not operate after the initial operation, because there will not be a positive identification of the mark.
[0052] The patient may be alerted if the image collecting process has terminated before swallowing the capsule.
[0053] The fact that the system is inoperable when unauthorized components are being used and the fact that the patient is warned greatly contributes to the patient's safety.
[0054] It will be appreciated that algorithms and calculations are carried out by software or software means executable on computing means such as a computer or similar data processors, microprocessors, embedded processors, microcomputers, micrcontrollers etc.
[0055] The capsule may be utilized for diagnostic purposes or can be implemented in therapeutic processes. The capsule can also include any known system for collecting or releasing substances from or into the gastrointestinal tract environment, such that samples may be collected or medicaments may be released from the capsule at required points along the gastrointestinal tract. It will be appreciated that the image collecting process enables precise identification of required points and accurate localization of the capsule along the tract.
[0056] The method and packaging of the present invention enable safe activation of an image collecting process directly prior to use thereby providing safe, economic and facile use of components in an image collecting process.
[0057] It will be appreciated by persons skilled in the art that the present invention is not limited by what has been particularly shown and described herein above. Rather the scope of the invention is defined by the claims which follow:
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A method and system may activate an in-vivo capsule to perform image collection while the capsule is outside a body and held in a cup, the cup having a mark on its inner wall. A processor may attempt to identify the mark, and terminate the image collection if the mark is not identified
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BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for inserting, in the molding of frames, metal staples adapted to retain laminar supporting elements for pictures, photographs and the like.
It is known that in order to frame pictures there are commercially available frames which comprise a rectangular molding formed by assembled strips which are internally provided with a flange which acts as abutment for the glass plate designed to protect the picture to be framed and for a panel of cardboard or the like adapted to support the picture at the rear. In order to retain the panel and the glass plate within the frame, flexible metal staples are inserted behind the panel by means of a mechanical or pneumatic fixing tool which is usually of the manual type.
The staples are inserted only partially, so as to have an end which protrudes toward the inside of the frame so that it can be folded back when the panel is to be removed or folded forward again in order to reposition the panel.
SUMMARY OF THE INVENTION
The aim of the present invention is to provide an apparatus by means of which the cardboard and the glass plate can be fixed automatically within a picture-frame molding.
This aim is achieved with an apparatus for inserting, in the molding of picture-frames, metal staples adapted to retain laminar backing elements for pictures, photographs and the like, characterized in that it comprises a beam which is arranged horizontally above the surface that supports said molding, two fixing tools which are guided on said beam transversely to two opposite sides of said molding, means for adjusting the distance between said fixing tools along said beam as a function of the distance between said sides, and means for vertically actuating said fixing tools into the position for applying metallic staples in said sides.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics and advantages of the present invention will become apparent from the following detailed description of a preferred embodiment, illustrated only by way of non-limitative example in the accompanying drawings, wherein:
FIGS. 1 and 2 are perspective views of the apparatus;
FIG. 3 is a front view of the apparatus of FIGS. 1 and 2;
FIG. 4 is a view of the head of the fixing tool in the position for inserting the staples in the molding;
FIG. 5 is a perspective view of an apparatus provided by combining in an in-line configuration two apparatuses according to FIGS. 1-4 for automatically preparing frames;
FIG. 6 is an enlarged-scale view of a detail of the apparatus of FIG. 5;
FIG. 7 is a sectional view of a further embodiment of the apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIGS. 1-6, the apparatus is generally designated by the reference numeral 1 and comprises a conveyor for supporting and conveying the frames which is constituted by a belt 2 which is closed in a loop around two rollers 3 and 4 ; the roller 4 is actuated in order to drive the belt with a continuous motion in the direction A. The rollers 3 and 4 are rotatably supported in sides 5 and 6 which rest on the footing 7 by means of spacers 8 .
Two vertical posts 9 rise from the side 6 and blocks 10 can slide thereon. Respective stems 11 are guided in the blocks 10 at right angles to the direction A, and a guiding edge 12 is fixed thereto.
In this manner, by moving and fixing the blocks 10 on the posts 9 and the stems 11 in the blocks 10 it is possible to adjust the edge 12 vertically and laterally.
On the opposite side of the belt 2 with respect to the guiding edge 12 there is another guiding edge 13 which is parallel to the edge 12 .
The guiding edge 13 is fixed, in a downward region, to a carriage 14 which is guided on a beam 15 running horizontally and at right angles to the direction A above the belt 2 .
The beam 15 cantilevers out from the top of a column 16 which rises from the footing 7 externally with respect to the side 5 .
The carriage 14 can be positioned on the beam 15 by means of a drive which comprises a reversible motor 17 which is supported in a cantilevered arrangement by the column 16 and actuates a threaded rod 18 which is engaged in the carriage 14 below the beam 15 . By actuating the rod 18 in one direction or the other it is possible to move the edge 13 closer or further away with respect to the edge 12 , depending on the width of the frame to be prepared.
In FIGS. 1-3, the frame comprises a conventional rectangular molding 19 made of wood or other similar material, which is composed by joining at right angles two transverse strips 20 and two longitudinal strips 21 . The strips 20 , 21 have a cross-section which forms a flange 22 (see FIG. 4) which lies inside the molding 19 and whereon there rest, for example, a glass plate 23 and a rear panel 24 , between which the picture to be framed is to be interposed. The glass plate may of course be omitted and the panel may have any kind of structure. In FIGS. 1-3, the panel that closes the frame to the rear is not shown for the sake of clarity.
In addition to the carriage 14 , two sliding blocks 25 , 26 are slidingly supported on the beam 15 .
The sliding block 25 can move along the beam through a transmission system which comprises a threaded stem 27 which lies within a seat of the beam 15 and is actuated by a reversible motor 28 . The stem 27 is rotatably engaged in the sliding block 25 , so that by actuating the motor 28 the sliding block 25 can be moved along the beam 15 in one direction or the other.
Two brackets protrude laterally to the beam 15 from the sliding block 25 and two parallel and vertical guiding rods 29 are fixed between them. A slider 30 is slidingly guided on the rods 29 , and a fixing tool 31 of the conventional type is rigidly fixed on said slider. The fixing tool 31 comprises an insertion head 32 (see FIG. 4) which has a nozzle 33 for firing the metal staples to be driven into the molding, said staples being joined so as to form a pack which is accommodated in the magazine 34 .
The slider 30 can be raised and lowered along the guiding rods 29 of the sliding block 25 by means of a transmission system which is composed of a reversible motor 35 which actuates a threaded stem 36 which is parallel to the guiding rods 29 and is rotatably engaged in the slider 30 .
The sliding block 26 is actuated along the beam 15 exactly like the sliding block 25 by means of a reversible motor 37 and a threaded stem (not shown in the drawing) which is actuated by the motor 37 and engages the sliding block 26 with a screw-type coupling.
The sliding block 26 also supports a fixing tool 38 which is fitted on a slider which can be positioned vertically by means of a transmission system which is fully identical to the transmission system that actuates the slider 30 and is actuated by a reversible motor 39 . Only the motor 39 of said transmission system is shown in the drawing; said motor actuates, by means of the threaded stem, the lifting of the slider on which the fixing tool 38 is fitted.
The fixing tools 31 , 38 are orientated so that by descending from a raised position by means of the motors 35 , 39 the nozzles of said fixing tools are directed toward the internal face 40 of the longitudinal strips 21 of the molding, above the rear panel 24 .
The operation of the above-described apparatus is as follows.
Assume an initial position in which the guiding edge 13 is already arranged, with respect to the opposite guiding edge 12 , at a distance which allows to guide the molding 19 between them without appreciable transverse plays with respect to the advancement direction A. Assume, furthermore, that the nozzles of the fixing tools 31 , 38 are vertically aligned on the internal flanges 22 of the longitudinal strips 21 and are raised with respect to the level of the belt 2 , so as to allow the molding 19 to pass below them.
In this situation, when a molding 19 has been conveyed by the belt 2 until it reaches the position in which the fixing tools 31 are arranged inside the molding, the motors 35 and 39 are activated so as to lower the sliders 30 to a level at which the nozzles 33 of the fixing tools 31 , 38 are engaged in the corner formed by the panel 24 and by the internal face 40 for containing the panel 24 on the flange 22 .
At this point, the fixing tools 31 , 38 are activated and drive the staples into the longitudinal strips 21 , thus locking said panels 24 against the flange 22 with the glass plate 23 interposed. Once this step for the insertion of the metal staples has been completed, the fixing tools 31 , 38 are again raised above the molding 19 , so as to allow it to continue further. A prerogative of the present invention is the fact that the arrangement of the fixing tools 31 , 38 at the level for inserting the staples can be achieved by means of adapted sensors which, after detecting the presence of the molding 19 on the belt 2 , actuate the gearmotors 35 , 39 so as to lower the fixing tools 31 , 38 .
In a preferred embodiment of the invention, conceived in order to adapt the apparatus to the width of the moldings, particularly when it is necessary to work with molding of different sizes, provisions are made for the use of additional sensors which are capable of detecting the transverse dimensions of the moldings 19 conveyed by the belt 20 and to accordingly actuate the gearmotors 17 , 28 , 37 so as to adapt the distance between the guiding edges 13 and 12 to the width of the molding as detected by the sensors and move the sliding blocks 25 , 26 so as to achieve the vertical alignment of the nozzles of the fixing units 31 , 38 on the flanges 22 at the longitudinal strips 21 .
The above-described apparatus can be operatively associated with another identical one in order to produce a unit which allows to insert metal staples on all the sides of the molding.
For this purpose, as shown in FIG. 5, at the outlet of the belt 2 of a first apparatus 1 there is a turntable 41 which is capable of turning through 90° the moldings transferred onto it by the belt 2 . Advantageously, the turntable 41 is constituted by a plurality of belts 42 (see FIG. 6) which are closed in a loop around corresponding pulleys and whose upper portion forms a supporting surface for the moldings 19 that arrive from the belt 2 . The belts are actuated with a decreasing motion from one side to the other, so as to turn through 90° the molding that rests temporarily on them, so that the longitudinal strips 21 arrange themselves transversely to the advancement direction A. Downstream of the turntable 41 there is a second apparatus 1 ′ which inserts the metal staples on the transverse strips 20 , which are now longitudinal. At the output of the second apparatus 1 there is a conveyor 43 which removes the completed moldings. Optionally, instead of the conveyor 43 it is possible to provide an additional turntable in order to return the moldings to the initial arrangement.
FIG. 7 is a sectional view of a further embodiment of the invention, in which the lifting and lowering of the slider 30 by means of the threaded stem 36 is combined with the movement actuated by a pneumatic cylinder 42 a.
For this purpose, the threaded stem 36 is screwed into a tube 43 which is guided axially, but retained rotationally, through a cylindrical cavity 44 formed in the slider 30 . A piston 45 is rigidly coupled on the tube 43 and divides the cavity 44 into two chambers. By feeding compressed air to the upper or lower chamber, the slider 30 is made to rise or descend, respectively. This allows to use the motors 35 , 39 for molding size changes and the pneumatic cylinders for raising and lowering the fixing tools during normal working conditions.
In practice, the turntable 41 is provided with guiding edges in order to facilitate and improve the precision of the rotation of the moldings in transit.
Advantageously, the speed at which the frames move on the turntable is at least twice the speed with which the frames advance on the conveyor of the apparatuses for inserting the fixing elements, in order to allow correct mutual spacing of the frames and their rotation through 90°.
The disclosures in Italian Patent Application No. BO99A000013 from which this application claims priority are incorporated herein by reference.
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An apparatus for inserting, in the molding of picture-frames, metal staples adapted to retain laminar backing elements for pictures, photographs and the like, comprising a beam which is arranged horizontally above the surface that supports the molding, two fixing tools which are guided on the beam transversely to two opposite sides of the molding, an actuation for adjusting the distance between the fixing tools along the beam as a function of the distance between the sides, and a further actuation for vertically actuating the fixing tools into the position for applying metallic staples in the sides.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application is a continuation-in-part of pending application Ser. No. 11/450,834 filed 9 Jun. 2006.
BACKGROUND OF THE INVENTION
[0002] Polyamide curing agents are utilized extensively in many markets for epoxy curing agents including coatings, adhesives, composites, and flooring applications. Polyamide curing agents comprise the reaction products of dimerized fatty acid (dimer acid) and polyethyleneamines, and usually a certain amount of monomeric fatty acid which helps to control molecular weight and viscosity. “Dimerized” or “dimer” or “polymerized” fatty acid refers, in a general way, to polymerized acids obtained from unsaturated fatty acids. They are described more fully in T. E. Breuer, ‘Dimer Acids’, in J. I. Kroschwitz (ed.), Kirk - Othmer Encyclopedia of Chemical Technology, 4 th Ed., Wiley, New York, 1993, Vol. 8, pp. 223-237.
[0003] Dimer acid is usually prepared by the acid catalyzed oligomerization under pressure of certain monomeric unsaturated fatty acids, usually tall oil fatty acid (TOFA), though sometimes other vegetable acids such as soya fatty acid or cottonseed fatty acid are used. Commercial products generally consist of mostly (>70%) dimeric species, with the rest consisting mostly of trimers and higher oligomers, along with small amounts (generally less than 5%) of monomeric fatty acids. Common monofunctional unsaturated C16 to C22 fatty acids also employed with the dimer acids in making polyamides include tall oil fatty acid (TOFA), soya fatty acid, cottonseed fatty acid or the like.
[0004] Any of the higher polyethylene polyamines can be employed in the preparation of polyamide curing agents, such as diethylenetriamine (DETA), triethylenetetramine (TETA), tetraethylenepentamine (TEPA), pentaethylenehexamine (PEHA), hexaethyleneheptamine (HEHA), and the like, though in actual commercial practice the polyethylene polyamine most commonly employed is TETA.
[0005] In addition, other monofunctional or difunctional carboxylic acids, or other multifunctional amines may be incorporated into the condensation process in order to provide specialized property enhancements.
[0006] Polyethylene polyamines are currently manufactured from the reaction of ammonia with either ethylene dichloride or ethanolamine. As new manufacturing assets are built to produce polyethylene polyamines, there is a tendency to favor the ethanolamine process, as it is less corrosive to the manufacturing equipment, and hence more economical. Unfortunately, the ethanolamine process generally produces less TETA than the ethylene dichloride process, and therefore prices for TETA are increasing relative to the prices for other polyethylene polyamines. There is therefore a need for more economical alternatives to TETA in the manufacture of polyamide curing agents. However, it would be advantageous if such an amine would have a molecular weight, amine hydrogen functionality, and chemical structure similar to TETA so as to minimize difficulties in re-formulation of end use products such as coatings and adhesives.
[0007] U.S. Pat. No. 2,705,223 describes epoxy resins cured with polyamides based on polymeric fatty acids and polyethyleneamines.
[0008] GB 2,031,431 discloses epoxy resins cured with mixtures of high molecular weight polyoxyalkylene polyamines and N,N′-bis(3-aminopropyl)ethylenediamine.
[0009] U.S. pat. No. 4,463,157 discloses self-curing amide-group-containing aminourea resins produced from a polyaminoamide which has been produced from polyalkylene-polyamines reacted with fatty acids and/or from polyalkylene-polyamines reacted with dimer fatty acids. Table 1 of this patent shows the product of reaction of N,N′-bis(3-aminopropyl)ethylenediamine with ricinene fatty acid.
[0010] EP 134,970 describes similar polyaminoamides.
BRIEF SUMMARY OF THE INVENTION
[0011] The present invention provides polyamide curing agent compositions comprising the reaction product of (1) an amine component comprising at least one multifunctional amine of structure 1
[0000]
[0000] where R 1 is CH2CH2CH2NH2; R 2 , R 3 and R 4 independently are H or CH2CH2CH2N and X is CH2CH2 or CH2CH2CH2 with (2) a dimer fatty acid or ester component, optionally, containing a monofunctional fatty acid.
[0012] In one aspect of the invention R 2 and R 3 are not H simultaneously.
[0013] In another aspect of the invention, the amine component that is reacted with the dimer fatty acid or ester component comprises a mixture of mono-, di-, tri- and tetra-substituted amines of structure 1 in a parts by weight (pbw) ratio of 0 to 50 pbw mono-substituted amine, 50 to 95 pbw di-substituted amine and 0 to 50 pbw tri-substituted amine and 0 to 25 pbw tetra-substituted amine, preferably a ratio of 0 to 20 pbw mono-substituted amine, 60 to 95 pbw di-substituted amine, 0 to 20 pbw tri-substituted amine and 0 to 10 pbw tetra-substituted amine.
[0014] In a further aspect of the invention the polyamide curing agent composition, i.e., the reaction product of the amine component and the dimer fatty acid component, comprises at least 15 mole % tetrahydropyrimidine-containing components.
[0015] As yet another aspect of the invention, there are provided epoxy systems, or compositions, comprising the contact product of the above polyamide curing agent, or curative, and an epoxy resin.
[0016] As an advantage of the current invention, the polyamide curing agent compositions for epoxy resins often provide faster cure speed than polyamide curing agents of the current art. As another advantage of the current invention, curing agent compositions are provided which do not contain triethylenetetramine, but which have physical properties including viscosity, molecular weight and amine hydrogen equivalent weight that closely resemble polyamides derived from triethylenetetramine.
[0017] The curing agent compositions are useful for crosslinking epoxy resins to produce coatings, adhesives, floorings, composites and other articles. Thus, another embodiment of the invention comprises coatings, adhesives, floorings, composites, and other cured epoxy articles prepared by curing epoxy resins using such curing agents.
[0018] As yet another advantage, when the polyamide curing agent composition contains at least 15 mole % tetrahydropyrimidine-containing components, the curing agent composition affords 2-component polyamide coatings manifesting good coating appearance and fast dry speeds, in many instances dry through times of less than 24 hours.
DETAILED DESCRIPTION OF THE INVENTION
[0019] “Dimerized” or “dimer” or “polymerized” fatty acid refers, in a general way, to polymerized acids obtained from unsaturated fatty acids. They are described more fully in T. E. Breuer, as noted above, which description is incorporated by reference. Common monofunctional unsaturated fatty acids used in making the dimer acid compositions include tall oil fatty acid (TOFA), soya fatty acid and cottonseed fatty acid. The dimer acids are prepared by polymerizing the fatty acids under pressure, and then removing most of the unreacted fatty mono-acids by distillation. The final product comprises mostly dimeric acids, but includes trimeric as well as some higher acids. The ratio of dimeric acids to trimeric and higher acids is variable, depending on processing conditions and the unsaturated acid feedstock. The dimer acid may also be further processed by, for example, hydrogenation, which reduces the degree of unsaturation and the color of the product.
[0020] Suitable for the purposes of the present invention are dimer acids with a dimer content as measured by GC ranging from about 50 wt % to about 95 wt %, and a trimer and higher acid content of from about 3 wt % to about 40 wt %, the remainder being monomeric fatty acids. However, as the amount of trimer acid is increased, it will be necessary to increase the amount of polyamine and/or the amount of fatty mono-acid in order to maintain the desired viscosity of the final product, since the higher functionality of the trimeric and higher fatty acids will lead to more branching and increase the molecular weight in the product, and may even gel the product, as will be appreciated by those skilled in the art. Esters of dimer acids, particularly the C1 to C4 alkyl esters, can also be employed in the current invention.
[0021] Preferred dimer acid components are those with a range of dimeric acids from 75 wt % to 90 wt %, including Empol® 1018 and Empol 1019® (Cognis Corp.), Haridimer 250S (Harima M.I.D., Inc.), Yonglin YLD-70 (Jiangsu Yonglin Chemical Oil Co.), and Unidyme® 18 (Arizona Chemical Co.).
[0022] The fatty acids used in the current invention in combination with the dimer acids include C8 to C22, preferably C16 to C22 mono-carboxylic acids containing from 0 to about 4 units of unsaturation. Usually, such fatty acids will be mixtures derived from triglycerides of natural products, such as babassu, castor, coconut, corn, cottonseed, grapeseed, hempseed, kapok, linseed, wild mustard, oiticica, olive, ouri-curi, palm, palm kernel, peanut, perilla, poppyseed, rapeseed, safflower, sesame, soybean, sugarcane, sunflower, tall, teaseed, tung, uchuba, or walnut oils. Pure fatty acids or mixtures of pure fatty acids, such as stearic, palmitic, oleic, linoleic, linolenic, etc. acids may also be employed, as can various esters of any of these fatty acids, particularly the C1 to C4 esters. Also of utility is isostearic acid, also known as monomer acid. Monomer acid is the mostly C18 fatty mono-acid stream derived from the preparation of dimer acid.
[0023] The preferred fatty acids to be blended with the dimer acids are tall oil fatty acid and soya fatty acid.
[0024] If desired, other monofunctional and multifunctional carboxylic acids may be incorporated into the dimer acid portion of the reaction composition.
[0025] The multifunctional amines of structure 1 of the current invention include N-3-aminopropyl ethylenediamine; N,N′-bis(3-aminopropyl)ethylenediamine; N,N-bis(3-aminopropyl)ethylenediamine; N,N,N′-tris(3-aminopropyl)ethylenediamine; N,N,N′,N′-tetrakis(3-aminopropyl)ethylenediamine; dipropylene triamine; N-3-aminopropyl-1,3-diaminopropane; N,N′-bis(3-aminopropyl)-1,3-diaminopropane; N,N-bis(3-aminopropyl)-1,3-diaminopropane; and N,N,N′-tris(3-aminopropyl)-1,3-diaminopropane; tetrakis(3-aminopropyl)-1,3-diaminopropane; and mixtures of these amines. These multifunctional amines can be prepared by the Michael reaction of either ethylene diamine or 1,3-diaminopropane with acrylonitrile, followed by hydrogenation over metal catalysts as is well known to those skilled in the art.
[0026] A preferred multifunctional amine for use as the amine component is N,N′-bis(3-aminopropyl)ethylenediamine. Most preferred as the amine component is a mixture comprising 0-20 pbw of N-3-aminopropyl ethylenediamine, 60-95 pbw of N,N′-bis(3-aminopropyl)ethylenediamine, 0-20 pbw of N,N,N′-tris(3-aminopropyl)ethylenediamine and 0-10 pbw of N,N,N′,N′-tetrakis(3-aminopropyl)ethylenediamine. Such a mixture can be prepared by the reaction sequence described above for making the multifunctional amine without the need to conduct a distillation or other process of separation, except for the optional removal of low molecular weight side products of the reaction which are more volatile than N-3-aminopropyl ethylenediamine. It will be recognized by those skilled in the art that small quantities of other products of hydrogenation may be present in the mixture.
[0027] If desired, the curing agent composition may be modified by incorporation of other multifunctional amines. Examples include ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, higher polyethyleneamines, aminoethylpiperazine, meta-xylylene diamine, the various isomers of diamine-cyclohexane, isophorone diamine, 3,3′-dimethyl-4,4′-diaminodicyclohexyl methane, 4,4′-diaminodicyclohexyl methane, 2,4′-diaminodicyclohexyl methane, the mixture of methylene bridged poly(cyclohexyl-aromatic)amines (MBPCAA) described in U.S. Pat. No. 5,280,091, 1,2-propylene diamine, 1,3-propylene diamine, 1,4-butanediamine, 1,5-pentanediamine, 1,3-pentanediamine, 1,6-hexanediamine, 3,3,5-trimethyl-1,6-hexane-diamine, 3,5,5-trimethyl-1,6-hexanediamine, 2-methyl-1,5-pentanediamine, bis-(3-amino-propyl)amine, N,N′-bis-(3-aminopropyl)-1,2-ethanediamine, N-(3-aminopropyl)-1,2-ethanediamine, 1,2-diaminocyclohexane, 1,3-diaminocyclohexane, 1,4-diamino-cyclohexane, the poly(alkylene oxide)diamines and triamines (such as for example Jeffamine D-230, Jeffamine D-400, Jeffamine D-2000, Jeffamine D-4000, Jeffamine T-403, Jeffamine EDR-148, Jeffamine EDR-192, Jeffamine C-346, Jeffamine ED-600, Jeffamine ED-900, Jeffamine ED-2001 and also aminopropylated ethylene glycols, propanediols, butanediols, hexanediols, polyethylene glycols, polypropylene glycols and polybutanediols. The polyamide curative composition can either be modified by incorporating these polyamines in the condensation reaction with the dimer acid, or by adding them to the polyamide after completion of the condensation reaction. In the former case, it is then necessary to adjust the ratio of moles of polyamine to equivalents of acid to conform with the guidelines given below.
[0028] The percentage of equivalents of fatty mono-acids to total equivalents of monofunctional plus multifunctional acids can be varied from 0 to about 30%, preferably from 3% to 20. The equivalents of acid can be obtained by titration of the starting materials with alcoholic hydroxide, as is well known in the art. Those skilled in the art will recognize that increasing the percentage of monofunctional acid will lower the molecular weight and viscosity of the polyamide. They will also recognize that increasing the trimer and higher acid content of the dimer acid will increase the molecular weight and viscosity of the polyamide.
[0029] The ratio of total moles of multifunctional amine to equivalents of acid, along with the functionality of the multifunctional amine, are crucial parameters in determining the molecular weight, viscosity, and other properties of the resulting polyamides. Indeed, if the ratio of amine to acid is not large enough, then the entire composition can gel. Furthermore, this ratio also influences the amine hydrogen equivalent weight (AHEW) of the final product, and has an effect upon the amount of unreacted multifunctional amine present after completion of the condensation reaction. Unreacted multifunctional amine can cause deleterious effects to surface appearance and intercoat adhesion. Suitable ratios of moles of multifunctional amine to equivalents of acid range from about 0.4:1 to about 1.2:1, preferably from 0.5:1 to 1:1. The moles of amine is calculated from the number average molecular weight, if a mixture of amines is employed.
[0030] Polyamides of the current invention can be manufactured by any number of processes known to those skilled in the art. Normally, the amines and acids are combined at temperatures ranging from about room temperature to about 100° C. Heat is then supplied to raise the temperature as water is condensed from the reaction mixture. Heating is normally continued until the specified amount of water is removed that will yield a product with the desired amide and imidazoline or tetrahydropyrimidine content. Optionally, vacuum can be applied particularly in the late stages of the process to aid in the removal of water from the mixture. To reduce foaming, which can be a problem particularly under vacuum conditions, small amounts of defoamers may be added to the polyamide composition. Appropriate defoamers include various acrylic copolymers containing 2-ethylhexyl acrylate as part of the copolymer composition, various polysiloxane copolymers, and the like.
[0031] During the condensation reaction, it is possible to cause some of the amine functional amides to cyclize with further loss of water to form tetrahydropyrimidines, as shown below for tetrahydropyrimidines. Driving the reaction to form higher levels of tetrahydropyrimidines may influence the properties of the polyamide curing agent, such as, for instance, improving cure speed and improving the appearance of the coating. All possible levels of tetrahydropyrimidine functionality of the polyamide curing agents are considered to be part of the current invention. However, in one desirable aspect the polyamide curing agent composition comprises at least 15 mole % tetrahydropyrimidine-containing components, preferably at least 20 mole % and especially at least 25 mole % tetrahydropyrimidine-containing components, as determined by 13C NMR. In some aspects an upper limit for the tetrahydropyrimidine-containing components would be 75 mole %.
[0000]
[0032] The polyamide curing agent, or hardener, is combined with an epoxy resin which is a polyepoxy compound containing about 2 or more 1,2-epoxy groups per molecule. Such epoxides are described in Y. Tanaka, “Synthesis and Characteristics of Epoxides”, in C. A. May, ed., Epoxy Resins Chemistry and Technology (Marcel Dekker, 1988), and are incorporated by reference. Such combination of polyamide curing agent and epoxy resin composes a curable epoxy system.
[0033] The preferred polyepoxy compounds are the diglycidyl ethers of bisphenol-A, the advanced diglycidyl ethers of bisphenol-A, the diglycidyl ethers of bisphenol-F, and the epoxy novolac resins.
[0034] To reduce the viscosity of a given formulation of polyamides of the current invention with a di- or multi-functional epoxy resin, the epoxy resin may be modified with a portion of monofunctional epoxide. In this way viscosity is further reduced, which may be advantageous in certain cases, such as for example to increase the level of pigment in a formulation while still allowing easy application, or to allow the use of a higher molecular weight epoxy resin. Examples of useful monoepoxides include styrene oxide, cyclohexene oxide, ethylene oxide, propylene oxide, butylene oxide, and the glycidyl ethers of phenol, the cresols, tert-butylphenol and other alkyl phenols, butanol, 2-ethyl-hexanol, and C8 to C14 alcohols and the like.
[0035] Polyamides of the current invention would normally be formulated with epoxy resins at stoichiometric ratios of epoxy groups to amine hydrogen ranging from about 1.5 to 1 to about 1 to 1.5. More preferred are ranges from 1.2 to 1 to 1 to 1.2.
[0036] It is also possible to modify the polyamides of the current invention by reacting a modest portion of the amine hydrogen with difunctional and monofunctional epoxy resins such as those described above. This is a common practice well known to those skilled in the art, and generally referred to as “adduction”. By adducting with difunctional and monofunctional epoxy resins it is possible to improve the compatibility of the polyamide with epoxy resin and thereby reduce problems such as blush, carbonation and exudation as described above, and to increase pot life. On the other hand, such modification tends to increase viscosity, particularly in the case of difunctional epoxy resins, and may in some cases also decrease the rate of cure. Particularly useful epoxy resins for adduction include the diglycidyl ethers of bisphenol-A, the advanced diglycidyl ethers of bisphenol-A, the diglycidyl ethers of and bisphenol-F, styrene oxide, cyclohexene oxide, and the glycidyl ethers of phenol, the cresols, tert-butylphenol and other alkyl phenols, butanol, 2-ethylhexanol, and C8 to C14 alcohols and the like. It is also possible to accomplish a modest level of adduction by mixing the amine and epoxy components and allowing them to stand for some period of time known as an induction period to those skilled in the art, normally 15 to 60 minutes, before application.
[0037] In some circumstances it may be advantageous to incorporate so-called accelerators for the epoxy-amine curing reaction in formulations based on polyamides of the current invention. Such accelerators are described in H. Lee and K. Neville, Handbook of Epoxy Resins, McGraw-Hill, New York, 1967. Suitable accelerators include various organic acids, alcohols, phenols, tertiary amines, hydroxylamines, and the like. Particularly useful accelerators include benzyl alcohol, phenol, alkyl substituted phenols such as nonylphenol, octylphenol, t-butylphenol, cresol and the like, bisphenol-A, salicylic acid, dimethylaminomethylphenol, bis(dimethylaminomethyl)phenol, and tris(dimethylaminomethyl)phenol. Normally, such accelerators are used at levels of 10% or less based on the total weight of binder, and more usually at levels of less than 5%.
[0038] In some circumstances it may be advantageous to incorporate plasticizers for the epoxy-amine network in formulations based on polyamides of the current invention. This is particularly useful in cases where, in the absence of such a plasticizer, the glass transition temperature, Tg, of the composition significantly exceeds the ambient temperature before the degree of reaction necessary to meet certain requirements such as solvent and chemical resistance and tensile strength has been achieved. Such plasticizers are well known to those skilled in the art, and are described more fully in D. F. Cadogan and C. J. Howick, ‘Plasticizers’, in J. I. Kroschwitz, ed., Kirk - Othmer Encyclopedia of Chemical Technology, 4 th Ed., Wiley, New York, 1996, Vol. 19, pp. 258-290. Particularly useful plasticizers include benzyl alcohol, nonylphenol, and various esters of phthalic acid. The ester plasticizers would normally be incorporated in the same package as the epoxy resin to minimize reaction with the amine curing agent. Another particularly useful class of plasticizers are hydrocarbon resins, which include toluene-formaldhyde condensates such as Epodil® L, xylene-formaldehyde condensates such as Nikanol® Y50, coumarone-indene resins, and many other hydrocarbon resin modifiers well know to those skilled in the art.
[0039] Coatings prepared from polyamides of the current invention and epoxy resins can be formulated with a wide variety of ingredients well known to those skilled in the art of coating formulation, including solvents, fillers, pigments, pigment dispersing agents, rheology modifiers, thixotropes, flow and leveling aids, defoamers, etc. Mixtures of solvents will frequently be chosen so as to give the best evaporation rate profile for the system while maintaining solubility of the binder components. Suitable solvents include aromatics, aliphatics, esters, ketones, ethers, alcohols, glycols, glycol ethers, and the like. Particularly useful in the formulation are some level of ketones such as acetone, methyl ethyl ketone, methyl isoamyl ketone, methyl propyl ketone, methyl amyl ketone, diacetone alcohol and the like, which can be used to improve pot life with little or no sacrifice in dry speed. If ester solvents are included in the formulation, it is usually necessary to formulate them in the package containing the epoxy resin, so as to minimize their reaction with the amine curing agent. Sometimes the epoxy resins used in the practice of this invention will be supplied in solvent cut versions, and likewise, it may be of value to use the polyamides of the current invention, or other curing agents used in combination with these polyamides, as solvent-cut versions.
[0040] Coatings of this invention can be applied by any number of techniques including spray, brush, roller, paint mitt, and the like. Numerous substrates are suitable for application of coatings of this invention with proper surface preparation, as is well understood in the art. Such substrates include but are not limited to many types of metal, particularly steel and aluminum, as well as concrete.
[0041] Coatings of this invention can be applied and cured at ambient temperatures ranging from about 0° C. to about 50° C., with temperatures of 10° C. to 40° C. preferred. If desired, these coatings can also be force cured at temperatures up to 150° C. or more.
EXAMPLE 1
Synthesis of 3-aminopropyl-1,3-diaminopropane
[0042] To a batch reactor was added 510.4 g of acrylonitrile and 6 g of water. The contents were heated to 60° C. To this mixture was added 85 g of ammonia over 5 hours. The reactor pressure was maintained at 2.4 MPa to keep the ammonia liquid. Once the ammonia addition was completed the reactor temperature was maintained for an additional two hours. The reactor was then cooled and the contents were emptied to yield 572.5 g of the intermediate product.
[0043] A 1 liter batch reactor was charged with 100 g of isopropanol and 3.9 g of Raney Co catalyst. The reactor was pressure cycled first with nitrogen and then with hydrogen to remove any traces of entrained air. After pressure cycling, the reactor was filled with 5.5 MPa hydrogen and heated to 120° C. Then 260 g of product from the previous step was added to the reactor over 4 hours. During this time reactor pressure was maintained at 5.5 MPa by supplying hydrogen to it from a one liter ballast tank. Once the addition was over the temperature was maintained at 120° C. for an additional hour to make sure the hydrogenation was complete.
[0044] The reactor was cooled down to room temperature, and the product was filtered. The product was analyzed by area percent GC and it contained 74% 3-aminopropyl-1,3-diaminopropane and 14% 1,3-diaminopropane.
EXAMPLE 2
Synthesis of Polyamide from Example 1
[0045] To a one liter glass reactor, 380.6 g of dimer acid (Pripol 1012, Uniqema) was added while purging the system slowly with nitrogen. The stirrer was started after the addition of dimer acid and 47.3 g of TOFA (Sylfat FA-1, Arizona Chemical Co.) was added slowly to this system. Next 110.4 g of the product from Example 1 was added over ten minutes and the stirrer rate was increased to 100 rpm. The contents were then heated to 250° C. and 36.5 g of water was removed by distillation. The reactor was cooled down to 140° C. and at this point 263.3 g of xylene was added and the reactor was further cooled to less than 80° C. and finally 122.5 g of isobutyl alcohol was added. The final product was golden-brown in color. The product had an AHEW of 502.
EXAMPLE 3
Synthesis of Mixture of N-3-aminopropyl ethylenediamine, N,N′-bis(3-aminopropyl)ethylenediamine, and N,N,N′-tris(3-aminopropyl)ethylenediamine
[0046] To a 1 liter batch reactor was added 236 g of ethylenediamine and to that 5 g of water was added, and the contents were heated to 60° C. To this mixture 417 g of acrylonitrile was added over 5 hours. Once the acrylonitrile addition was completed the reactor temperature was maintained for an additional 1.5 hours.
[0047] A 1 liter batch reactor was charged with 100 g of isopropanol, 6.6 g of water and 7.5 g of Raney Co catalyst. The reactor was pressure cycled first with nitrogen and then with hydrogen to remove any traces of entrained air. After pressure cycling, the reactor was filled with 5.5 MPa hydrogen and then heated to 120° C. The 500 g of product from the previous step was the added to the reactor over 4 hours. During this time reactor pressure was maintained at 5.5 MPa by supplying hydrogen to it from a one liter ballast tank. Once the addition was over the temperature was maintained at 120° C. for an additional hour to make sure the hydrogenation was complete.
[0048] The reactor was cooled down to room temperature, and the product was filtered. The product was analyzed by area percent GC and it contained 6% N-3-aminopropyl ethylenediamine, 80% N,N′-bis(3-aminopropyl)ethylenediamine, and 11% N,N,N′-tris(3-aminopropyl)ethylenediamine and 2% N,N.N′,N′-tetrakis(3-aminopropyl)ethylenediamine.
EXAMPLE 4
Synthesis of Polyamide from Example 3
[0049] To a one liter glass reactor, 445.0 g of dimer acid (Yonglin YLD-70) was added while purging the system slowly with nitrogen. The stirrer was started after the addition of the dimer acid and 51.0 g of TOFA (Sylfat FA-1 was added slowly to this system. Next 299.4 g of the Example 3 product was added over ten minutes and the stirrer rate was increased to 100 rpm. The contents were then heated to 265° C. and 56.0 g of water was removed by distillation. The reactor was cooled to 65° C. and the contents were emptied to a glass bottle. The final product had an amine value of 361 mg KOH/g, a viscosity of 30,000 mPa·s, a Gardner color of 8 and a calculated amine hydrogen equivalent weight (AHEW) of 110.
EXAMPLE 5
Synthesis of Polyamide from a Mixture of Example 3 and Ethylenediamine
[0050] To a one liter glass reactor, 234.9 g of Empol 1018 dimer acid (Cognis) was added while purging the system slowly with nitrogen. The stirrer was started and 26.7 g of TOFA (Sylfat FA-2) was added slowly. Next was added 124.8 g of the amine mixture of Example 3 and 15.6 g of ethylenediamine over ten minutes and the stirrer rate was increased to 100 rpm. The contents were then heated to 265° C. and 27.6 g of water was removed by distillation. The reactor was cooled to 65° C. and the contents were emptied to a glass bottle. The final product had an amine value of 341 mg KOH/g and a viscosity of 36,640 mPa·s.
EXAMPLE 6
Synthesis of Higher Molecular Weight Polyamide from Example 3
[0051] To a reactor was added 232 g of Example 3, 106 g of TOFA (Sylfat FA-2) and 572 g of Empol 1018 dimer acid (Cognis). The mixture was heated to 160° C., and which point water began to distill. Over 2 hr., the mixture was heated to 215° C., at which point the pressure was reduced to 150 torr. The temperature was raised to 230° C. over 30 min. The temperature was held until 53.0 g of water had been removed, at which point the contents were cooled. The final product had an amine value of 150 mg KOH/g and a viscosity of 473,600 mPa·s.
EXAMPLES 7-9
Coating Formulations and Properties
[0052] A pigmented resin base was prepared in a standard manner by charging 98.8 g of DER® 331 epoxy resin (Dow Chemical Co., EEW=190) and 3.5 g Nuosperse® 657 (Elementis pic) to a dispersion vessel. The vessel was equipped with a high speed mixer employing a Cowles blade. To this 100.8 g TiPure® R900 titanium dioxide (E. I. DuPont de Nemours Co.) and 74.8 g of Luzenac® 10M2 (Luzenac Group) were added under high shear (approx. 4000 rpm) over a 5-10 minute period with a further period of 20-30 minutes dispersion before dilution of this with 71.7 g xylene and 17.9 g butanol followed by further blending for about 5 minutes at lower shear (1000 rpm). This formulated resin base has a viscosity of 200-300 mPa·s and an epoxy equivalent weight of approx. 710.
[0053] The resin base was combined with the curing agents indicated in following Table 1 by hand mixing. After mixing and an induction time of 15 minutes coatings were applied to glass panels at 175 microns wet film thickness using a bird-bar applicator. The coated glass panels were evaluated for:
a) Thin Film Set Time using a Beck Koller drying time recorder at a constant temperature of 23° C. and 60% relative humidity. Phase II and Phase III drying times were assigned according to ASTM D5895. b) Persoz pendulum hardness using a BYK pendulum hardness tester to ISO 1522 standard. c) Specular gloss was measured using a BYK Micro Tri Gloss model No. 4520 to ISO 2813 standard.
[0057] All results are shown in Table 1.
[0000]
TABLE 1
Example
7
8
9
Polyamide Curing Agent
Ancamide ®
Example 4
Example 5
350A
Formulation
Curing Agent Wt. (g)
6.0
6.0
6.0
Resin Base Wt. (g)
37.2
37.2
37.2
PVC %
25
25
25
Mix Solids (wt & vol %)
78 & 65
78 & 65
78 & 65
Handling
Mix Viscosity @ 23° C.
Properties
(mPa · s)
0 minutes
455
415
390
30 minutes
610
690
640
Coating
Thin Film Set @ 23° C.
Performance
BK - Phase II (hr.)
6.5
3.0
3.5
BK - Phase III (hr.)
8.0
3.5
4.0
Persoz Hardness @ 23° C.
1 day
40
70
85
2 day
110
105
115
7 day
155
140
155
Specular Gloss
20°/60°
24/70
25/73
10/45
[0058] Ancamide® 350A curative is a polyamide curing agent based on dimer acid, TOFA and TETA which is available from Air Products and Chemicals, Inc., with a viscosity of 15,000 mPa·s, a Gardner color of 7, an amine value of 360 to 390 mg KOH/g, and an AHEW of 110.
[0059] The Thin Film Set Times at 23° C. of coatings derived from the current invention (Examples 8 and 9) are significantly faster than Example 7; with the times taken to reach Phase II and Phase III approximately half of the standard TETA based polyamide (Ancamide® 350A). This is an indication that the current invention exhibits earlier hardness development which may lead to the ability to handle coated components sooner and overcoat quicker, providing the opportunity to increase productivity within the coatings application. The early hardness development is also shown by the one day hardness being significantly higher for Examples 8 and 9 compared to Example 7, with 7 day hardness being comparable. The Example 4 curing agent, however, had an AHEW and amine value within the specified range of the comparative commercially available TETA based polyamide. Though the viscosity of the polyamide of Example 4 was higher than that of the comparative hardener, it surprisingly led to a mixed viscosity that was slightly lower. It is the mix viscosity that determines the applicability of the product, and therefore the ultimate solvent content or VOC of the coating, indicating another advantage of the polyamides of the current invention over those of the current art.
EXAMPLE 10
[0060] Dimer acid (Uniquema Pripol 1017) 576 g, N,N′-bis-(3-aminopropyl)ethylenediamine composition (Example 3 reaction product) 366 g and TOFA (Sylfat FA-2) 70 g were mixed together and then heated to 166° C. At 166° C., 18 g of water was removed using a distillation column. When there was no further water in the column, the reactor temperature was increased to 214° C. and a further 10 g of water was removed making the total water take off 28 g. Also, 300 g of the reaction product (Sample 1) was removed for analytical work. Once there was no water remaining in the column, the temperature was raised to 232° C., and the reactor pressure lowered to 150 mm Hg. Under these conditions an additional 10 g of water was removed and collected in the receiver, resulting in a total water take off 38 g. At this point another 100 g of polyamide material was sampled for analysis (Sample 2). Finally, the reactor was heated to 240° C., and the pressure lowered to 25 mm Hg. Under these conditions an additional 11 g of water (49 grams total) was removed and a final sample of the polyamide was taken (Sample 3). Samples 1, 2 and 3 were subjected to 13C NMR analysis to determine the polyamide and the pyrimidine content.
[0061] Each sample of the polyamide reaction product was mixed with Epon 828 resin (Bisphenol A diglycidyl ether resin; 190 EEW) at 55 parts by weight per hundred parts Epon 828 resin (phr) until a homogeneous mixture was obtained and after a 30 min aging period the mixtures were cast onto a BK recorder glass plate using a die applicator at 150 microns to make a epoxy-polyamide film. The scale of the BK recorder was set at 24 hrs. The observations for dry-hard and dry-through values were recorded according to the ASTM method for drying times (ASTM D 5895-96).
[0062] The analytical results of the respective properties are shown below.
[0000]
Sample #
1
2
3
Polyamide Product Composition
Polyamide - amide content
100
87
76
(mole %)
Tetrahydropyrimidine content
0
13
24
by NMR (mole %)
Coating Performance
Dry-Hard (hr)
10
8
6.5
Dry-Through (hr)
>24
>24
12.5
Appearance
opaque
opaque
good
[0063] As shown in the results above, it is clear that 2-component epoxy-polyamide films, or coatings, that contain zero to low levels of the pyrimidine ring structure did not give desirable coating properties, such as the appearance, hard dry and dry-through times. It is very important in the coatings industry for 2 component polyamide coatings to demonstrate good coating appearance and fast dry speeds at ambient temperature for improved return to service of the article that has undergone painting. Therefore, to have epoxy systems with ultimate dry through times <24 hr is a recognized performance benefit in the industry. The results clearly show that for desirable properties, polyamide curing agent compositions with greater than about 15 mole % pyrimidine structure content are necessary, as determined by 13C NMR.
[0064] Thus, another feature of an aspect of the invention is that the curing agent composition manifests a dry through time of less than 24 hours according ASTM D 5895-96 when mixed with liquid Bisphenol A diglycidyl ether epoxy resin (Epon 828 or Dow DER 331) having an EEW of 190 at 55 phr until homogenous, allowed to mature for 30 minutes and coated at 150 microns.
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The present invention provides polyamide curing agent compositions comprising the reaction products of (1) multifunctional amines of structure 1
where R 1 is CH2CH2CH2NH2; R 2 , R 3 and R 4 independently are H or CH2CH2CH2NH2, and X is CH2CH2 or CH2CH2CH2 with (2) dimer fatty acids, optionally in combination with monofunctional fatty acids, the reaction product preferably comprising at least 15 wt % tetrahydropyrimidine-containing components. The curing agent compositions are useful for crosslinking epoxy resins to produce coatings, adhesives, floorings, composites and other articles.
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TECHNICAL FIELD
The field of the invention relates to the removal of polymer coatings, exemplarily, poly-para-xylylene and its derivatives.
BACKGROUND OF THE INVENTION
It is a frequent practice in the semiconductor industry to apply a protective polymer coating over a finished or semi-finished product, e.g., completely configured printed circuit (PC) boards with integrated circuits (ICs) mounted thereon. A frequently used protective polymer is parylene, which provides a conformal coating that is easily applied. In many cases it is necessary to remove the coating at some later time, e.g., to make changes or repairs on the circuit board. Though its ease of application and its coverage capabilities make parylene a desirable coating material, it is extremely difficult to remove.
Parylene is a generic name for members of a series of polymerized paraxylylenes whose basic member is poly-para-xylylene, commonly known as parylene-N. The monomer of poly-para-xylylene consists of a benzene ring bonded to two methyl groups to create a linear molecule. A second member of the series is poly-monochloro-para-xylylene, known as parylene-C. Poly-monochloro-para-xylylene is a variation of poly-para-xylylene wherein the variation consists of a single chlorine atom substituting for one of the aromatic hydrogens in the benzene ring of the monomer molecule. A third member of the series is poly-dichloro-para-xylylene, commonly known as parylene-D. The member of the series known as parylene-E (poly-ethyl-para-xylylene) has an ethyl group in place of the chlorine in poly-monochloro-para-xylylene. More generally, parylene-E contains an alkyl group substituted for the ethyl group. Additionally, fluorinated parylenes are commonly referred to as parylene-F. Throughout this text, the term parylene will be used in a generic sense and will refer to poly-para-xylylene, its derivatives, and co-polymers.
Poly-para-xylylene and poly-monochloro-para-xylylene are generally deposited with substantially the same process. Exemplarily, either dimer is vaporized at approximately 250° C. The dimer is then pyrolized at about 680° C. into a monomer, which is allowed to diffuse at room temperature into a deposition chamber where it condenses and polymerizes on the surface of everything in the chamber in a conformal manner. The low temperature deposition and complete coverage properties of parylene make it very useful as a protective coating. Parylene as a protective coating for electronic printed circuit boards is especially advantageous. See, for instance, R. Olson, Proceedings of the 17th Electrical/Electronics Insulation Conference, pp. 288-290, 1985, and U.S. Pat. No. 4,123,308, both incorporated herein by reference.
Poly-monochloro-para-xylylene has a lower water absorption rate, lower coefficient of thermal expansion, and generally forms a more pinhole free film than poly-para-xylylene. In addition, the inclusion of one chlorine atom on each benzene ring of the polymer chain makes poly-monochloro-para-xylylene extremely resistant to solvents. Though this makes parylene-C a very good protective coating, it also makes the repair of assemblies and/or subassemblies difficult if the coating must be removed.
Parylene-E, on the other hand, can be dissolved, though with some difficulty, in some solvents such as xylene, toluene, hexane, methylene chloride, and chloroform. The mixing of parylene-E and parylene-C allows for the engineering of the solvent resistance of a coating while retaining some of the protective benefits of the moisture and insulation properties of parylene-C. Methods of coating removal, other than mixing with sufficient parylene-E to permit solvent removal, are available. These include abrasion, chemical-aided removal, and plasma etching in an oxygen barrel reactor; however, these methods have also not proved completely satisfactory.
Use of abrasion techniques runs the risk of damaging coated electronic and mechanical parts adjacent to the coating being removed, and of generating dirt and dust that may be difficult to remove. Chemical-aided parylene removal methods, such as those used in U.S. Pat. No. 4,734,300, still require physical means to remove a coating from an article, subjecting the article to possible damage from the physical means applied. The use of a chemical, for instance, tetrahydrofuran in the aforementioned patent, can result in the chemical attack of coatings and components adjacent to and under the coating being removed. Plasma etching in an oxygen barrel reactor typically is slow requiring long processing times. For instance, U.S. Pat. No. 4,123,308 discloses that parylene exposed to an oxygen plasma is typically etched at the rate of 1000 Å per minute. This rate, in many cases, is too low for removing parylene from PC boards in a manufacturing environment. In addition, ions in the plasma can cause damage to electronic components, exemplarily due to electrostatic discharge (ESD) that can result from bombardment by the energetic ions.
Plasma etchers have been developed that separate the plasma generating section from the reaction chamber in which the etching takes place. This allows for the generation of plasma discharge products, a gas of reactive atoms and molecules, without electrons and ions bombarding the body being etched. In addition, the reaction from the contact of the plasma discharge products with the body is downstream from the plasma source. Some configurations of this type of "downstream" plasma etcher have used microwave generators as the plasma source to more efficiently couple energy into the plasma. Such microwave plasma etchers are described, for example, in U.S. Pat. No. 4,673,456, U.S. Pat. No. 4,138,306, U.S. Pat. No. 4,175,235, and U.S. Pat. No. 4,776,923. U.S. Pat. No. 4,776,923 also describes a method in which ultraviolet radiation generated in the plasma generating section is prevented from impinging on the body by the use of a bent path connecting the plasma generating section with the reaction chamber. Plasma etchers, including the types described in the aforementioned patents, have been used for the removal of SiO 2 , Si 3 N 4 , photoresists, and polyimide from silicon wafers using a variety of gases such as O 2 , H 2 , N 2 O, CF 4 , NF 3 , and SF 6 and mixtures thereof.
Studies have shown that the etch rate for polyimide and photoresists from silicon wafers is increased by addition of N 2 O, CF 4 , or SF 6 to an oxygen gas flow in a plasma etcher. As the percentage of oxygen in the flow is decreased (percentage of the additive is increased), the etch rate typically increases to a maximum. Beyond the maximum etch rate, further decreasing the percentage of oxygen in the gas flow typically results in a rapidly decreasing etch rate. As pointed out by M. A. Hartney et al., Journal of Vacuum Science and Technology, B, Vol. 7, No. 1, pp. 1-13, 1989, in a CF 4 /O 2 gas flow the maximum etch rate for photoresists and polyimides usually occurs in the range of 20% to 30% CF 4 , with a sharp peak about this maximum. Similarly, etching polyimides in a SF 6 /O 2 gas flow exhibits a sharp maximum etch rate at about 5% SF 6 (see, for instance, Emmi, F. et al., Proceedings of the Fifth Symposium on Plasma Processing , Vol. 85-1 of the Electrochemical Society, pp. 193-205, 1985). The percentage of the CF 4 or the SF 6 associated with the maximum in the polyimide etch rates has been determined to be, among other factors, a function of substrate temperature, gas flow rate, and generator power (applicable to either RF or microwave generators). Studies of the etching of polyimides and photoresists can be found in a series of articles in the Proceedings of the Fifth Symposium on Plasma Processing Vol. 85-1 of the Electrochemical Society, 1985 (for instance, Emmi, F. et al., pp. 193-205, Robinson, B. et al., pp. 206-215, Yogi, T. et al., pp. 216-226, and Charlet, B. et al., pp. 227-234).
Parylene is a unique material, being one of the few polymers capable of forming a conformal coating that is truly solvent resistant. In addition, unlike polyimide, parylene is a semi-crystalline material (i.e. it has a well defined melting temperature). As previously mentioned, several techniques have been applied to remove parylene coatings, but none has proven totally satisfactory.
In view of the desirability of parylene as a coating material, a method for quickly removing parylene from a body or selected areas of a body, while causing substantially no damage to the body or subassemblies of the body, would be of great significance. This application discloses such a method.
SUMMARY OF THE INVENTION
The inventive method involves fabricating or modifying (including repairing) an article comprising a body that comprises, at least some time during the fabrication or modification, a polymer layer. The fabrication or modification includes removing at least a portion of the polymer layer by a plasma etching process. The polymer is a member of the group consisting of poly-para-xylylene, its derivatives, and copolymers (collectively "parylene").
A gas mixture containing oxygen, a second gas, and one or more optional additives is directed into a plasma chamber. The second gas is selected from the group consisting of the fluorocarbons of general formula C x F y , with x and y being integers, 1≦x≦4 and 1≦y≦12; fluorosulfides of general formula S r F t , with r and t being integers, 1≦r≦3 and 1≦t≦16; and chlorofluorocarbons of general formula C u F v Cl w , with u, v, and w being integers, 1≦u≦2, 1≦v≦2, and 1≦w≦2. The additives are chosen from a group consisting of N 2 O, He, Ne, Ar, Kr, and Xe. The optional additives comprise by volume at most 60% of the total gas mixture. The percentages of oxygen and the second gases generally depend on the combination of gases being used in the gas mixture. Typically, the percentages of the gases generally fall into the following ranges: oxygen between 30% and 90%, total fluorocarbon content between 10% and 70%, total fluorosulfide content between 1% and 10%, and total chlorofluorocarbon content between 2% and 20%.
A plasma is generated in the plasma chamber by microwave means, whereby plasma discharge products are produced. Some of the plasma discharge products enter a reaction chamber that holds the body and is downstream from the plasma chamber, connected to the plasma chamber by tubular means. The plasma discharge products react with at least a portion of the polymer of the body, resulting in an exhaust gas comprising reaction by-products and unreacted plasma discharge products. In an exemplary embodiment of the inventive method, the exhaust gas is caused to exit the reaction chamber through an exit located adjacent to the back of the body. After removing at least a portion of the polymer, the fabrication or modification of the article is completed.
Significantly, the inventive process makes possible parylene removal at a relatively high rate, and with substantially no damage to adjacent components or materials. It is also significant that the process permits relatively rapid removal of a parylene coating from relatively large bodies, for example, from bodies that are the size of printed circuit boards.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically depicts an exemplary plasma etching system for practicing the inventive method;
FIG. 2 shows exemplary data on the removal rate of poly-monochloro-para-xylylene from silicon wafers for various gas mixtures;
FIG. 3 shows exemplary data on the removal rate of poly-monochloro-para-xylylene from silicon wafers with increasing percentage of argon usage in a SF 6 /O 2 /N 2 O/Ar gas mixture;
FIG. 4 presents exemplary data on the removal rate of poly-monochloro-para-xylylene from silicon wafers as a function of the pressure;
FIG. 5 illustrates the temperature dependence of the removal rate of poly-monochloro-para-xylylene from silicon wafers; and
FIG. 6 schematically depicts an exemplary plasma etching system adapted for selectively etching a body according to the inventive method.
DETAILED DESCRIPTION
The inventive method can, inter alia, be applied to the repair of printed circuit boards that are, exemplarily, subassemblies of an electronic or telecommunications system, since the method is applicable to removing, selectively if desired, parylene coatings from large area component substrates such as PC boards. Repair of PC boards includes repair, replacement, and addition of components. Although repair of PC boards is a currently preferred use of the inventive method, the method is not so limited. For instance, the method can also be used advantageously in semiconductor device manufacture, if parylene is used to form dielectric and/or passivation regions of an IC.
In the context of this and the following discussions, "body" refers to a member that comprises, at least at some stage during the process of fabricating or modifying the article, a parylene layer. The term encompasses such members as semiconductor substrates, electronic devices, PC boards configured or partially configured with components, and other mounting and housing units for electronic and telecommunications devices, subassemblies, and systems. In a preferred embodiment, "body" refers to a PC board at least partially configured. In another embodiment, "body" refers to a member containing layers of different materials which are being processed to form a semiconductor device such as an integrated circuit.
FIG. 1 schematically depicts an exemplary plasma etching system for practicing the inventive method. Inlet 1 is the entrance for a mixture of gases to the plasma chamber 2 where plasma discharge products are produced from interaction of electromagnetic energy with the gases. The electromagnetic energy is supplied by a microwave source (not shown). Tubular means 3 connect the plasma chamber with a reaction chamber 7. The body 10 being etched is situated on a heating platform 5 in the reaction chamber such that at least a portion of the body is contacted by plasma discharge products flowing from the plasma chamber. The system is provided with an exit 6 connected to a vacuum pump (not shown) to remove the exhaust gas formed from the reaction of the plasma discharge products with the body.
In a preferred embodiment, the gas flow introduced to the system at 1 consists of a CF 4 /O 2 mixture. Typically, commercially available CF 4 is mixed with oxygen, commonly (depending on the company suppling the mixture) with approximately 8.5% oxygen by volume. The CF 4 gas of FIG. 2 is CF 4 :O 2 with about 8.5% oxygen but is labeled CF 4 for brevity. In the preferred embodiment, the CF 4 content (containing about 8.5% O 2 ) is in the range 20-50% of the total flow.
The gas mixture flows into a plasma chamber 2 which contains a microwave cavity area where a plasma is generated, with energy transferred to atoms and molecules of the gas mixture forming plasma discharge products. The efficiency of this energy transfer is a major aspect of the rapid removal rate of parylene obtainable by means of the inventive method. In an exemplarily preferred embodiment, the means for generating a plasma comprises a microwave source, with approximately 2.45 GHz power output frequency, having a full wave rectified power supply. Additionally, the power supply is a switching DC power supply with less than about 1% ripple in the power output, and having 0.1% feedback regulation or better of output power. It has been determined that etching rates are frequently substantially improved when using a full wave rectified power supply rather than a more conventional half wave rectified power supply. However, the inventive method does not require use of a full wave rectified power supply, but can be carried out with other known, stable sources of microwave power.
From the plasma chamber, some of the plasma discharge products flow toward a reaction chamber 7 which contains the body to be etched. Significantly, the plasma chamber and the reaction chamber are not co-located, but are connected by tubular means 3. This prevents the body from being exposed to energetic ions which are present in the plasma chamber and may cause damage to the body. In a preferred embodiment, the tubular means includes at least one bend such that there is no line of sight connection from the microwave plasma within the plasma chamber to the reaction chamber. Thus, ultraviolet radiation generated in the plasma is prevented from interacting with the body.
Plasma discharge products are directed towards the body, preferably, by a gas containment sleeve 4 located at the inlet to the reaction chamber. They react with the polymer, etching it. FIG. 2 shows exemplary etch rates for poly-monochloro-para-xylylene on silicon wafers for various gas mixtures. Significantly, the etch rates for parylene resulting from application of the inventive method are substantially greater than typical etch rates attained by prior art methods of plasma etching. Of course, for a given plasma etching system, the etch rate is generally dependent on the total surface area of the body being etched. SF 6 /O 2 /N 2 O typically produces a higher etch rate than CF 4 /O 2 , but CF 4 is more common, more stable, and easier to handle than SF 6 , making, as previously mentioned, CF 4 /O 2 a currently preferred gas mixture. As indicated in FIG. 2, the etch rates for CF 4 /O 2 mixtures with 20% and 50% CF 4 in the total flow are not substantially different. In a CF 4 /O 2 mixture, etch rates typically do not drop substantially until the percentage of CF 4 in the gas mixture significantly differs from the 20%-50% range, e.g., mixtures with 5% or 85% CF 4 .
Other fluorocarbons, C x F y , or fluorosulfides, S r , F t , can be used in an oxygen mixture. Additionally, it is believed that chlorofluorocarbons, C u F v Cl w , which are used in semiconductor processing, can be used in combination with oxygen. Use of chlorofluorocarbons is especially advantageous when the article being fabricated is a semiconductor device, since it reduces the variety of gases used in the fabrication process. However, in all applications the second gas is selected from those stoichiometric compounds that are gaseous at room temperature.
For the most part, the optional additives included in the gas mixture are inert gases. These gases typically do not chemically react with the parylene, but are believed to assist in the transfer of energy to the reactive gases forming the plasma discharge products. FIG. 3 shows exemplary data on the removal rate of poly-monochloro-para-xylylene from silicon wafers with increasing percentage of argon usage in a SF 6 /O 2 /N 2 O/Ar gas mixture. In the gas mixtures represented by FIG. 3, the percentage of oxygen in the mixture decreases as the percentage of argon increases, maintaining the SF 6 and the N 2 O content of the total gas flow at approximately 4% and 10%, respectively. As indicated in FIG. 3, the addition of Ar to the process gas mixture, SF 6 /O 2 /N 2 O, results in an increased etching rate until the volume of Ar in the total gas flow reaches about 45%. Beyond about 50% Ar content in the gas flow (about 60% total additives in the gas mixture), the etching rate is projected to decrease at a significant rate.
N 2 O also can be an additive to the gas flow since it supplies oxygen for the oxidative reaction on the body surface. In a further currently preferred embodiment, a CF 4 /O 2 gas mixture is used in the etching process until the removal of the parylene is nearly complete. Then the CF 4 /O 2 mixture is replaced by a N 2 O/O 2 gas mixture. Use of the N 2 O/O 2 gas mixture at the end of the etching process essentially cleans the parylene surface, removing residual fluorine that may adhere to the body surface.
Typically, the etch rate of parylene also can be significantly enhanced by increasing the body temperature. FIG. 5 shows the removal rate of poly-monochloro-para-xylylene from silicon wafers as a function of wafer temperature, using a N 2 O/SF 6 /O 2 gas mixture with approximate volume content 10%/7.5%/82.5%, respectively. In many cases it has been found advantageous to maintain the body at a relatively high temperature, whereby a relatively high removal rate can be obtained. Those skilled in the art will appreciate that considerations other than parylene removal rate (e.g. the presence of low melting point material) may limit the maximum acceptable temperature of the body. However, practice of the inventive method at room temperature also results typically in substantial etch rates. The inventive method can be advantageously practiced by mounting the body in the reaction chamber on a heated platform 5 (see FIG. 1) to control the body temperature. For embodiments in which a body, such as a PC board, has low thermal conductivity, the body can be heated by other means such as heating lamps.
Process pressure is also a factor in the etch rate of parylenes. FIG. 4 shows the etch rate of parylene-C from silicon wafers as a function of pressure in the reaction chamber, using a N 2 O/SF 6 /O 2 gas mixture with approximate volume content 10%/7.5%/82.5%, respectively. Typically, the pressure is measured near the reaction chamber exit, but just outside the reaction chamber. Above 4 torr the etch rate will continue to decrease below its maximum rate at pressure of about 2.5 torr. Typically, the efficiency of coupling energy into the gas mixture to form the reactive gases of the plasma discharge products decreases at higher pressures. In addition, the interaction of the reactive gases results in a neutralization process decreasing the amount of reactive species available for contact with the body. At higher pressures, the etch rate is significantly lower. In some embodiments, the inventive method can be advantageously practiced at higher pressures such as to remove the parylene at a relatively slow rate. For example, for etching parylene in IC fabrication, a relatively slow etch rate is desired to insure that the body is not overetched. For most embodiments, it is believed that pressures above about 100 torr will not produce useful etch rates. Thus, the inventive method is best practiced with the process pressure below 100 torr, preferably in the range 0.5-10 torr, exemplarily at about 2.5 torr, to attain high etch rates. Of course, there needs to be sufficient elemental and molecular species to react with the parylene. Below a pressure of about 0.05 torr, the concentrations of reactive gases are generally too low to produce useful etch rates.
Etching of the parylene results in reaction by-products that are exhausted from the reaction chamber along with unreacted plasma discharge products. In a preferred embodiment, the exhaust exit 6 (see FIG. 1) to a vacuum system is located directly in back of the body, the plasma discharge products contacting and etching the front of the body. With the exit so situated, the plasma discharge products are made to flow relatively uniformly over the entire body front surface. In addition, in this arrangement the exhaust gas is directed away from the front surface of body, reducing the possibility of depositing elements of the exhaust gas back on the front surface. However, to remove parylene from both sides of the body, the body can be suspended such that the plasma discharge products contact both the front and back of the body in approximately equal proportions. In this configuration, reactions at the front and back of the body generally contribute substantially equally to the formation of the exhaust gas.
Exemplarily, after removing parylene from a PC board, the board is further modified by such procedures as removing or repairing a defective component, replacing a defective component with a functioning component or adding new components which will incorporate additional features into the system comprising the PC board, re-coating at least a portion of the board with parylene, testing the electronic components on the PC board, and, possibly, again applying the modification process of the inventive method if testing indicates that the repaired or added components are not functioning satisfactorily.
FIG. 6 schematically depicts an exemplary etching system adapted for selectively etching a body in accordance with the inventive method. Plasma discharge products entering the reaction chamber are directed through a baffle box 8 to the body 10, which is mounted on a platform 13 resting on pins 14 and 15. The baffle box, which replaces the internal containment sleeve 4 (see FIG. 1), is a topless box-like structure with side walls which can be mounted to the top of the reaction chamber. The inlet to the reaction chamber is within the area defined by the baffle box walls and the top of the reaction chamber. The bottom of the baffle box consists of slides with variable size outlet holes. The location of the holes are patterned to correspond to the areas of the body to be etched. Virtually any pattern of holes can be made, including a pattern for etching an entire surface of a parylene-covered body. The baffle box is situated directly above the front 11 of the body such that the plasma discharge products pass through the holes in the baffle box and contact the body substantially only at the selected locations of the body. Optionally, to aid in the selective etching of the body, a "floor" 9 patterned with holes corresponding to the pattern of holes in the baffle box, is placed directly behind the back 12 of the body adjacent to the reaction chamber exit. With the exit to the evacuation system and with the path to the body so designed, the flow of plasma discharge products is restricted to flow across the body at the selected locations. The correspondence between the pattern of holes in the baffle box and the pattern of holes in the floor need not be a one-to-one correspondence, but can be any correspondence that produces a desired flow pattern in the reaction chamber.
Preferably, the bottom of the baffle box is made of quartz, and advantageously provides a conductive path (resulting from contact of the plasma discharge products with the walls forming the holes in the baffle box bottom) for removing heat from the plasma discharge products. However, quartz is susceptible to slow etching by the plasma discharge products. Coating the quartz baffle box (at least the bottom of the baffle box where the plasma discharge products flow through small holes) with a layer of tetrafluoroethylene (TFE) fluorocarbon polymers, fluorinated ethylene-propylene (FEP) resins, or copolymers of TFE and FEP will protect it, since these materials are substantially non-reactive with the plasma discharge products.
Essentially, the baffle box is a masking means. Other masking means can be used to selectively etch a portion of parylene from a body. This is especially advantageous in an embodiment wherein a semiconductor electronic device, such as an IC, is being fabricated, in accordance with the inventive method, with parylene being used in dielectric and passivation regions of the device. In correspondence with typical semiconductor processing that uses conventional polymers such as polyimide, parylene is formed as a layer over relatively large areas of the electronic chip. Subsequently, selective portions of the parylene layer are removed, e.g. to make possible the introduction of dopant materials to form electrically active regions. In addition, portions of parylene typically are removed to form vias and other electrically conducting paths through the parylene layers in the device. After removal of the parylene and subsequent deposit of metallization for the vias and conducting paths, if necessary, parylene is again deposited and the process is repeated to form additional device layers. A final layer of parylene may be deposited to form a passivation layer to protect the semiconductor device prior to undergoing packaging processes.
EXAMPLE 1
A layer of parylene, approximately 1 mil (25.4μ) thick, was removed from a 6 in. ×3 in. PC board configured with ICs using a downstream microwave plasma etching system. In the system, process gases are individually routed to a blend manifold where the gases are mixed. The manifold is connected to an essentially straight 1 in. diameter quartz tube by way of a 1/4 in. stainless steel tubing which is coupled to a 1/2 in. diameter neck for delivery of the gas mixture to the quartz tube. The quartz tube is connected to a 3 in. long, 1 in. diameter cylindrical microwave cavity where a microwave plasma is generated. Microwave power is supplied to the cavity using an ASTeX S-1000 microwave power source and ASTeX waveguide components. The S-1000 provides up to 1 kW CW of 2.45 GHz microwave power, regulated to 0.5% of output power with less than 1% ripple. A 1 in. diameter quartz tube with two essentially straight, parallel sections connected by two approximately 39° bends is used to connect the microwave cavity region with a reaction chamber. The quartz tube contacts the reaction chamber approximately 6 in. beyond the bend in the tube. The inlet to the reaction chamber is surrounded by a baffle box, interior to the reaction chamber. The baffle box walls are made of anodized aluminum and are mounted to the top of the reaction chamber extending approximately 2 in. into the reaction chamber. The plasma discharge products are confined in the baffle box with the only exit being through the bottom of the box. The bottom comprises quartz slides with variable size outlet holes. The temperature inside the reaction chamber is raised using heat lamps. In this system, the body to be processed is placed on a platform resting on pins connected to a floor having variable openings. A vacuum system is connected to the exit of the reaction chamber.
The process gases used to etch the PC board were introduced into the plasma chamber at the following rates in standard liters per minute (slm): 2 slm CF 4 (about 8.5% O 2 ), 2 slm O 2 , and 0.4 slm N 2 O. The baffle box was configured to etch the entire 6 in. ×3 in. surface of the PC board. The temperature of the PC board ranged from 90° C. to 140° C. during the removal process. The microwave source provided an output power of 500W. The pressure measured near the exit of the reaction chamber was around 3 torr. Under these conditions, the 25.4 μm layer of parylene was removed in about forty minutes.
EXAMPLE 2
A layer of parylene, 1 mil (25.4 μm) thick, was removed from a 4 in. silicon wafer with the same system as in Example 1 except that the baffle box was replaced by a containment sleeve. The containment sleeve is a 2" long 5" diameter tubing made of anodized aluminum.
The gas flow and pressure were the same as in Example 1. The wafer was maintained at a temperature of 110° C. The microwave source provided an output power of 300W. The 25.4μ parylene layer was removed from the silicon wafer in three minutes.
EXAMPLE 3
With the etching system, gas flow, microwave power, and pressure being the same as in Example 1, a layer of parylene, 0.75 mil (19 μm) thick, was removed, in approximately twenty minutes, from a 6 in. ×1 in. ceramic board containing a hybrid integrated circuit (HIC). The temperature of the ceramic board ranged from 90° C. to 130° C. during the removal process.
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Disclosed is a method for removing poly-para-xylylene, its derivatives, and copolymers (collectively called "parylene") from bodies, including relatively large bodies such as printed circuit (PC) boards, that is capable of yielding relatively high removal rates. A body such as a PC board coated with parylene is placed into a reaction chamber downstream from a microwave plasma such that plasma discharge products generated by the microwave plasma react with the parylene, etching the parylene without exposing the body to bombardment by energetic ions and/or electrons. The plasma is generated from a gas mixture containing oxygen, a second gas, and optional additives such as N 2 O, He,or Ar. The second gas is selected from the group consisting of fluorocarbons, fluorosulfides, and chlorofluorocarbons. A currently preferred second gas is CFR 4 . The inventive method is also applicable for fabricating articles such as integrated circuits and semiconductor devices that comprise a parylene layer.
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FIELD
[0001] The invention relates to electromagnetic actuators and servo-actuators.
BACKGROUND
[0002] Limited angle, brushless DC rotary actuators are well known and commercially available. One such actuator is disclosed in U.S. Pat. No. 5,512,871 issued Apr. 30, 1996. Another is disclosed in U.S. Pat. No. 6,313,553 issued Nov. 6, 2001.
[0003] The actuators now available and as presented by the above-identified references, are known commercially as “torque motors”, and include a ferromagnetic yoke attached to a magnet comprising the rotating member. The yoke is deemed necessary in order to strengthen the rotating member sufficiently for operation, and to close the attached magnet's magnetic circuit. But the presence of a yoke results in a structure with a high moment of inertia, reducing dynamic performance, and having a single-sided stator structure which creates unbalanced magnetic forces on the rotating member attracting it toward the stator.
[0004] One drawback of such an actuator is that approximately 20% or more of the power consumption is used to move its own inertia, reducing dynamic performance. Depending on the application duty cycle, this wasteful power consumption value can be even higher.
[0005] A second drawback is that due to the unbalanced design, the rotor magnet has a magnetic attraction force toward the stator structure, which leads to the use of an expensive thrust ball bearing to perform an axial stop function yet allowing the requisite rotational freedom of the rotor. A part of this axial attraction force is useful to withstand vibration when used in certain applications, but in any case the rotor rotation is subjected to friction torque such that some of the magnetic force used to create rotation and output torque is wasted.
[0006] A third drawback is the electromagnetic flux leakage. It can be clearly understood by seeing the structure of the prior art as in FIG. 1 and FIG. 2 , in that the 4 coils and stator poles are necessarily located very close to each other. Even with a small magnetic airgap between the rotor yoke and poles, when saturation appears at high currents necessary for the creation of high torque, most of the coil flux does not pass through the magnet, which would create the torque, but instead closes itself on the neighboring coil.
[0007] A fourth drawback is that in servo applications, the actuator magnet cannot be used to activate the position sensor receiver, but a second, separate magnet is required to be attached to the yoke, adding cost and weight to the rotating member.
[0008] A fifth drawback is that due to the physical space required for the construction and assembly of the stators and coils, the actual useful stroke of the prior art's 4-pole single-sided actuator is approximately 75 degrees compared to a theoretical stroke of 90 degrees, which would be preferable in most applications. Use of the prior art's 2-pole construction in the same physical actuator size could produce a 90 degree usable stroke, however the torque would be reduced by 50% rendering such an actuator undesirable and unusable in many applications. And, increasing the size of the actuator to attain the required torque would also render the actuator undesirable due to the resulting size, weight and cost.
SUMMARY OF THE INVENTION
[0009] The following definitions are applicable in describing the invention unless the context indicates otherwise, and are known and understood by those skilled in the art of motor design:
[0010] The term “stator” means a one or multi piece(s), high permeability ferromagnetic structure, which is fixed in linear or rotational motion.
[0011] The term “active stator” means a “stator” with poles and adapted to receive excitation coil windings to produce a magnetic flux.
[0012] The term “passive stator” means a “stator” that provides a path for a magnetic flux but does not incorporate any excitation coil windings. For example a “passive stator” can be high a permeability ferromagnetic plate.
[0013] The term “stator circuit” means an “active stator” plus excitation coils placed on the poles.
[0014] The term “stator assembly” means an overmolded “stator circuit” or an overmolded “passive stator”.
[0015] The term “airgap” or “magnetic airgap”, with notation E, means the distance between axially spaced stators absent the rotor.
[0016] The term “pole pair” means the north and south poles of a magnet.
[0017] The term “multipolar” means a magnet that has been magnetized to have more than one pole pair.
[0018] The term “rotor” or “rotor magnet” or “disc magnet rotor” means a multipolar disc magnet axially magnetized having pole pairs defined by a radial demarcation or transition line.
[0019] The term “application” means a device to which the actuator is attached and which is operated by the actuator.
[0020] The term “2 pole configuration” or “2 pole actuator” or the like means an embodiment in which there is at least a single 2 pole active stator on one side of the rotor and the rotor has two pole pairs.
[0021] The term “4 pole configuration” or “4 pole actuator” or the like means an embodiment in which there is at least a single 4 pole active stator on one side of the rotor and the rotor has four pole pairs.
[0022] The term “inertia assembly” means all the actuator parts that contribute to calculation of inertia for purposes of calculating the figure of merit AK.
[0023] The present invention in one embodiment relates to an electromagnetic actuator comprising a rotary single-phase actuator that can produce a substantially constant torque and a torque proportional to current, on a limited angular travel known as its useful stroke, said useful stroke typically between 60 degrees and 110 degrees. The actuator comprises stators including 2 or 4 poles that are axially spaced apart, facing each other and their spacing establishing an airgap and a rotor consisting of a magnetized multipolar disc magnet of 2 or 4 pole pairs in the airgap. Other features and embodiments will be described below.
[0024] In another embodiment, there is an active stator on one side of the rotor and a passive stator on the other side of the rotor.
[0025] The end points of the travel of the application to which the invention is connected, whether rotary or linear, are mechanically connected to the appropriate beginning and end points of the actuator's useful stroke. The rotation of the actuator can also be limited to its useful stroke by internal stops. Applications of the actuator use its output torque to provide direct rotary motion, or may use a rotary-to-linear mechanism such as a cam and follower or crank and slider to convert the rotary motion's torque to a linear motion force.
[0026] The invention produces a constant torque and a torque proportional to current over its useful stroke with equal or higher torque and faster dynamic response time, in a substantially equivalent size to actuators of the prior art. In one embodiment a 90° constant torque proportional to current, over a 90° useful stroke is available. In other embodiments a shorter stroke with constant torque is available.
[0027] The invention finds particular application in controlling various automotive applications, such as air control and exhaust gas recirculation valves, and turbocharger vanes and waste gates.
[0028] The invention is based on the realization that use of a stator on opposite sides of the rotor can enable greater dynamic effect than in the prior art in an equivalent size and space and avoid the problems seen in the prior art. In accordance with the principles of this invention, rather than attaching the rotating magnet to a ferromagnetic yoke, the yoke is eliminated. Two stationary, high permeability ferromagnetic magnetic stator assemblies, oppositely facing on either side of the rotor, are used. The use of stator assemblies on each side of the disc magnet rotor eliminates the ferromagnetic yoke utilized in the prior art.
[0029] When at least one stator assembly is energized, actuator torque is achieved because of the affect of the stator assembly' interaction with the rotor's magnetic field. In one embodiment the stator assemblies are alike; however embodiments with unlike stator assemblies are also useful as described below.
[0030] The invention utilizes an airgap E between the closest surfaces of the axially spaced apart oppositely facing stator assemblies with the disc magnet rotor in the airgap defining a spacing e 1 and e 2 on either side of the disc magnet rotor. In one embodiment, e 1 =e 2 . However, as will be seen in the following description, there are times when it is beneficial to have unequal spacing such that e 1 ≠e 2 .
[0031] In a magnetic structure such as this invention, there are “static” axial magnetic forces attracting the rotor magnet to the stator on each side, when there is no current applied to the stator excitation coils and also when the coils are energized. When current is applied to the coils, the coils are energized thereby generating their magnetic fields, and the interaction of those fields with the field of the rotor magnet creates the torque to rotate the shaft and drive the application.
[0032] Management of the axial forces between the rotor magnet and the adjacent stator assemblies on each side is a feature of the invention. The static axial magnetic forces acting between the rotor magnet and the stator assemblies are determined by the type of stator assembly used on each side of the rotor, and/or the axial location of the rotor in the airgap E. In some applications such as automotive applications, it may be desirable to introduce an axial “pre-load” force on the shaft to help counteract axial vibrations. The introduction of such a biasing force is easily accomplished in this invention either by locating the rotor slightly closer to one stator assembly, or using two somewhat dissimilar stator assemblies to exert unbalanced axial forces to bias the rotor toward one stator assembly. The introduction of such a biasing force does not reduce the output torque of this invention.
[0033] In an embodiment of the invention the positions of the stator assemblies on each side of the rotor is provided by a non-magnetic circular wrapping belt which has an inward-facing lip, which may be continuous or discontinuous, having a width equal to the magnetic airgap E. The lip has bearing surfaces against which the stator assemblies are seated thus allowing easy actuator assembly, and resulting in high dimensional precision, as well as low production cost. Thus, the magnetic airgap E is defined by the width of the inward-facing lip of the belt.
[0034] In an alternative embodiment, the stator assembly on one side of the rotor can be a suitable high permeability ferromagnetic plate (a passive stator) of a thickness which is chosen to close the magnetic circuit. If a high permeability ferromagnetic plate is used, the amount of actuator torque is reduced from that provided by the embodiments having active stators on each side of the rotor since there are no coils on the plate for creating additional magnet flux.
[0035] As described above the stator circuits are similarly overmolded in a non-magnetic material to make the stator assemblies, and along with the rotor and shaft, are assembled and connected by the aforementioned non-magnetic circular wrapping belt.
[0036] However, in another embodiment, in order to create an integrated stator assembly, the overmolding of a first stator circuit also incorporates on the base side of the stator circuit, commonly molded with the normal overmolding, portions of the belt that serve to allow attachment and spacing of the other stator assembly. The belt and a lip bearing surface along with mounting ears is commonly molded with the overmolding on the pole face side of the stator circuit to define the integrated stator assembly. There can be 2, 3, or 4 mounting ears, respectively spaced apart at 180°, 120°, or 90° as part of the common molding as well as other features of the belt that may be desired. In this embodiment, after assembling the rotor and shaft into the integrated stator assembly, the second separately overmolded stator assembly is seated against the belt's lip bearing surface to define the magnetic airgap E, again allowing easy assembly, high dimensional precision, and low production cost.
[0037] The non-magnetic wrapping belt and the spacing lip may contain an embedded rotor position sensor receiver, locating the sensor proximate to the actuator's magnetic airgap E, to receive varying magnetic field information utilizing the actuator rotor's magnetic flux. In this embodiment, the actuator rotor magnet either has a non-circular cross section, e.g. elliptical, in order to present a varying airgap and thus a varying magnetic field for the sensor, or has a particular magnetization pattern on its edge. This embodiment eliminates the need for locating a second emitter magnet and sensor receiver, with their attendant cost and space penalties, at one end of the actuator shaft.
[0038] Given the foregoing, the following basic description of a two-pole rotary actuator with two active stators according to the invention is provided. The output torque of the actuator is developed by applying the principles of the Lorentz Force Law, known to those skilled in the art of motor design. The rotor magnet is magnetized axially through its thickness. The magnetization is realized with a magnetizing head. The stator poles are wound with copper or aluminum magnet wire, but in opposite winding directions, so when energized, poles of different polarities will be induced in each stator assembly. A stator assembly is located on each side of the rotor being axially spaced apart and facing each other to define the airgap in which the rotor resides. When energized, the facing poles of the stator assemblies on each side of the rotor are of opposite polarity and each rotor magnet pole will be facing an opposite polarity stator pole. The magnetic flux created by the energized coils interacts with the magnetic flux of the rotor magnet to create the output torque of the actuator.
[0039] With a two pole design, the invention will have a total stroke of 180 degrees and within that stroke will be a 90 degree period where the torque is constant and proportional to the applied current. This is the useful area for control of various applications such as automotive air control valves, exhaust gas recirculation valves, and automotive variable geometry turbochargers and wastegates.
[0040] The invention can also be implemented in a 4 pole configuration, with 4 poles on at least one stator assembly having alternating polarity and 4 pole pairs in the rotor of alternating polarity. With a 4 pole design, the total stroke will be 90 degrees with a useful, constant torque and proportionality period of 50 degrees.
[0041] The rotor magnet, while high strength to withstand shock and vibration forces, has low inertia compared to prior art designs utilizing a ferromagnetic yoke. The employment of stator assemblies on each side of the rotor providing a concentrated magnetic flux to interact with the rotor provides high output torque. Thus, the dynamic performance of this invention is superior to prior art designs and provides much more precise control of the application to which it is applied along with more torque.
[0042] Other embodiments of the invention provide a means in the form of a belt with a lip to establish the airgap distance.
[0043] Other features and embodiments of the invention will be described below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] FIG. 1 is a cross-section view illustrative of a prior art actuator.
[0045] FIG. 2 is a view of a prior art stator, pole and coil configuration.
[0046] FIG. 3 shows a perspective view of an exemplary actuator of the present invention.
[0047] FIG. 4 is an exploded view of exemplary components for the present invention.
[0048] FIG. 5 is a perspective view of an exemplary stator structure of the present invention.
[0049] FIG. 6 is a perspective view of an exemplary stator circuit of the present invention.
[0050] FIG. 7 is a perspective view of an exemplary overmolded stator assembly of the present invention.
[0051] FIG. 8 is a cross section view through 8 - 8 of FIG. 3 .
[0052] FIG. 9 is a schematic side view from arrow A of FIG. 5 of the stator structure.
[0053] FIG. 10 a is a view showing a non-circular rotor magnet as the magnetic emitter with a sensor receiver located in the belt to determine rotor angular position.
[0054] FIG. 10 b is a schematic view showing a portion of the rotor having varying magnetization along a peripheral portion as the magnetic emitter with a sensor receiver located in the coupling belt to determine rotor angular position.
[0055] FIG. 11 is a perspective view of the coupling belt.
[0056] FIG. 12 is partial perspective view of the stator coupling belt.
[0057] FIG. 13 is an exploded perspective view of an embodiment of the present invention where the rotary position receiver is mounted to a printed circuit board or lead frame in the cover and a magnetic field emitter is mounted to the shaft.
[0058] FIGS. 14 a and 14 b show the operation of a 2 pole embodiment of the invention in which FIG. 14 a shows the ready position at −45° from the middle of the stator pole and FIG. 14 b shows the final position when the coils are energized, at +45° from the middle of the stator pole.
[0059] FIG. 15 is a graph of the torque curves for a 2 pole embodiment of the invention.
[0060] FIG. 16 a - 16 c show views of a 4 pole embodiment of the invention in which 16 a is a perspective view; 16 b shows the ready position at −25° from the middle of the stator pole; 16 c shows the final position when the coils are energized, at +25° from the middle of the stator pole.
[0061] FIG. 17 is a graph of the torque curves for the 4 pole embodiment of the invention
[0062] FIGS. 18 a - 18 c are views of an embodiment of the invention using 2 asymmetric stator structures in which FIG. 18 a is a perspective view of the assembled apparatus; 18 b is a perspective view of one the asymmetric stator structures of FIG. 18 a and FIG. 18 c is a perspective view of the other asymmetric stator structure of FIG. 18 a.
[0063] FIG. 19 is a view of an embodiment with an active stator on one side of the rotor and a passive stator in the form of a single plate on the opposite side of the rotor to close the magnetic circuit.
[0064] FIG. 20 is a view of an embodiment where the actuator is directly driving an air control valve in rotary motion.
[0065] FIG. 21 is a view of an integrated stator assembly embodiment in which the overmolding of one stator is commonly molded with the coupling belt.
[0066] FIG. 22 is a partial view of an embodiment in which the spacing lip is discontinuous.
DETAILED DESCRIPTION OF THE INVENTION
[0067] FIG. 1 is a cross section of an illustrative prior art actuator taken from FIG. 6 of U.S. Pat. No. 5,512,871. The actuator consists of a magnetized disc 102 which is glued to a ferromagnetic yoke 112 and thus constitutes the movable device 100 , which is connected to a coupling shaft 110 . The stationary part 108 comprises a stationary stator assembly. A thrust ball bearing 104 is necessary to limit the axial movement of the moveable device 100 toward the stationary stator assembly 108 . It is to be noted that the yoke rotates with the magnetized disc and thus introduces the problems mentioned above with respect to the prior art such as in U.S. Pat. No. 5,512,871 issued Apr. 30, 1996 and U.S. Pat. No. 6,313,553 the contents of which are incorporated in their entirety herein for all purposes.
[0068] FIG. 2 is a view of a prior art stator circuit and shows the stator poles 206 mechanically pressed into a stator base 200 . The four stator poles 206 each have a pole shoe 202 at the level of their heads in order to reach the maximum angular travel as close as possible to the ninety degree theoretical travel, which in the case of this prior art actuator is approximately only 75 degrees. The electric supply coils 204 used for generating the magnetic flux for the actuator are placed on each of the four stator poles 206 . When saturation appears at high currents for the desired creation of high torque, most of the coil 204 flux does not pass through the rotor magnet, which would create the torque, but instead closes itself on the neighboring coil 204 .
[0069] FIG. 3 shows a general view of the actuator 10 in an embodiment in accordance with the principles of this invention. The actuator comprises first and second like overmolded stator assemblies 12 and a coupling belt 14 and other components all as further described in FIG. 4 .
[0070] FIG. 4 is an exploded view of an exemplary embodiment of the present invention 10 . The actuator comprises first and second overmolded stator assemblies 12 , a coupling belt 14 and a magnetized disc rotor 16 . Disc rotor 16 is attached to shaft 18 by coupling member 20 to apply its rotation to the shaft. The rotor 16 is located in an airgap between the two stator assemblies 12 defined by the coupling belt 14 by an inward facing lip 22 and bearing surfaces 24 and 26 which are illustrated in FIGS. 8 , 11 and 12 . The first and second bearing surfaces 24 and 26 against which both stator assemblies 12 are seated defines the airgap E. Coupling belt 14 in one embodiment is configured as a sufficiently rigid circular belt as will become clearer hereinafter. It has cutout ears 28 with openings for engaging clips as will be described below. The stator assemblies 12 are positioned in the belt from opposite directions and seat on the corresponding bearing surfaces 24 and 26 , as shown, in a manner which defines a magnetic airgap E for disc magnet rotor 16 which is positioned with respect to the bearing surfaces 24 and 26 . The dimension e 1 and e 2 are the distances from the stator pole end faces 36 (see FIG. 5 ) to the facing surface of the rotor. In typical embodiments, disc magnet rotor 16 is located in the center of the magnetic airgap E equally spaced from the stator assemblies, that is, e 1 equals e 2 . It is understood that the shaft 18 is axially fixed with respect to the stator assemblies 12 , and that the rotor 16 is also axially fixed and coupled on the shaft 18 so that when the unit is assembled the rotor 16 is in an axially fixed position within the magnetic airgap E. In typical applications, the rotor 16 will be maintained without any net axial force due to the symmetry of the magnetic forces provided by equal spacing and axially symmetrical like stator assemblies on each side of the rotor. However, in certain applications of the invention such as when there is a vibration environment, it may be advantageous to introduce an axial force on the rotor 16 to resist vibration in one direction and thereby to help maintain the application's load in its axial location. To resist vibration in one direction, the location of disc magnet rotor 16 on the shaft 18 can be axially adjusted, toward either stator assembly 12 , to provide the desired axial force on the rotor 16 , with no reduction of output torque. Another means for inducing an axial force on the rotor 16 is described below with reference to FIGS. 18 a - 18 c . This adjustment of the axial force on the rotor can be implemented in both the 2 pole and the 4 pole configuration.
[0071] It is to be noted that in the applications for which this invention is intended, a high dynamic response capability is an important requirement in order to position the application in as short a time as possible. A measure of the ability of the actuator to produce the required torque and to position the application to its commanded position is provided by the use of figures of merit, and herein, a figure of merit AK is defined which has an absolute numerical value equal to or greater than about 1,000 and is calculated by the ratio of Motor Steepness divided by Motor Inertia J m , where Motor Steepness is equal to the square of the Motor Constant K m .
[0000]
AK
=
Motor
Steepness
Motor
Inertia
=
Motor
Constant
2
Motor
Inertia
≥
1
,
000
[0000] K m describes the motor's ability to produce output torque based on input electrical power and is an intrinsic figure of merit useful to compare different motors. K m is proportional to the ratio of output torque (T) to the square root of input power (W), i.e.
[0000]
K
m
=
T
W
.
[0000] J m is the sum of the rotor 16 inertia and the shaft 18 inertia and the coupling member 20 inertia as can be seen in FIG. 4 . Motor constant K m , Motor Steepness, Motor Inertia J m , Torque T and input power W are terms and figures of merit known to those skilled in the art of motor design.
[0072] An exemplary actuator of a 2 pole configuration as described herein may be constructed with parameters as in Table 1 to provide the figure of merit AK at least equal to 1,000. In the example given:
[0000]
AK
=
(
1.73
×
10
-
1
)
2
1.85
×
10
-
5
=
1
,
618
[0000]
TABLE 1
Torque Motor comparison
PRIOR ART
INVENTION
Magnet remanence
(T)
1.2
1.2
Torque constant = Kt
(Nm/A)
0.243
Terminal resistance
(Ohms)
1.98
Motor constant = Km peak
(Nm/W 1/2 )
1.50E−01
1.73E−01
Rth
° C./W
2.50
Continuous torque @ 25° C.
(Nm)
1.221
and 12 V
Continuous torque @ 130° C.
(Nm)
0.430
and 12 V
Peak torque @ 130° C. and
(Nm)
0.906
12 V
Stroke
(°)
75
>90
Electrical time constant
(ms)
9.5
4.3
Inertia
(kg.m 2 )
6.50E−05
1.85E−05
Mechanical time constant
(ms)
2.9
<1
Diameter
(mm)
60
60
total height
(mm)
50
72
total weight
(g)
640
550
Magnet weight
(g)
46
50
Iron weight stator
(g)
340
360
Iron weight rotor
(g)
140
0
Copper weight (all coils)
(g)
60
80
[0073] FIG. 5 is a view of the stator structure 30 of the present invention which advantageously may be made by the sintered powder metal process. In this exemplary version, the stator structure 30 has two poles 32 and a base 34 . The poles 32 have end faces 36 . The stator structure 30 defines a U-shaped configuration.
[0074] FIG. 6 is a view of a stator circuit 40 of a 2 pole configuration of the present invention showing coils 42 wound on molded bobbins 44 and terminated in pins 46 to provide access for electrical connection. The bobbins 44 are mounted on the poles 32 of the stator structure 30 .
[0075] FIG. 7 is a view of the overmolded stator assembly 12 of the present invention for a 2 pole configuration. In this view stator pole end faces 36 and coil connections 46 are visible.
[0076] The overmolding material 44 may be a thermoplastic polymer of the Liquid Crystal Polymer (LCP) type, a commercial example being Zenite, or a thermoplastic polyamide formulation, commercially known examples being Stanyl and Zytel. The overmolding 44 makes it possible to provide a mechanical connection of the overmolded stator assembly 12 with the belt 14 or a cover 48 ( FIG. 13 ) by the presence of fastener elements in the form of protruding grippers or clips 50 on which mating fastener elements in the form of cutout ears 52 ( FIG. 11 ) of the coupling belt 14 or the cutout ears 54 of the cover 48 ( FIG. 13 ) are fastened. While the mating fasteners hold the parts together, it is the lip 22 ( FIGS. 11 and 12 ) that defines the precise dimension of the airgap E. The airgap E is the distance between facing stator pole end faces, or between stator pole end faces on one side and a passive stator on the other side of the rotor as will be described in more detail below. In the present embodiment, because the overmolding is coplanar with the stator pole end faces, the dimension E is determined by the width of the lip 22 having its bearing surfaces 24 and 26 bearing on the overmolding of the stator assemblies. In any configuration the width of the lip may be adjusted to ensure that the dimension E is the distance between pole end faces or pole end faces and a passive stator as the case may be. It should be noted that in addition to the mechanical connection of the stator assemblies 12 with the coupling belt 14 , there is a magnetic axial force between the stator assemblies 12 and the rotor 16 which contributes to holding the actuator 10 together and in particular to cause the stator assemblies 12 to firmly seat on the bearing surfaces 24 and 26 of the lip 22 .
[0077] FIG. 8 is a cross section view through 8 - 8 of FIG. 7 . In this view, the U-shape of the cross section through the stator poles 36 is evident. The magnetic airgap E is determined by engagement of the lip sides 24 and 26 with the overmolded stator assemblies 12 . The magnetic flux circuit FC flows efficiently through the stators.
[0078] FIG. 9 is a schematic view along arrow A of FIG. 3 of the stator structure 30 showing the U-shaped cross section and defining key dimensions D and H. Dimension D is the spacing between the poles 36 and is in the range of about 2 to 5 times the magnetic airgap E, and preferably is about 4 times the magnetic airgap E providing sufficient spacing to prevent electromagnetic flux leakage between the energized coils. Dimension H is the height of the stator pole 36 above the base 34 and is less than about 8 times the magnetic airgap E and preferably about equal to or less than 6 times the magnetic airgap E allowing the energizing coil to have sufficient copper volume for operation of the invention.
[0079] It is also to be noted that prior art rotary actuators may also be equipped with angular position sensors. This type of configuration is often called a servo-actuator. Such a sensor requires an additional magnet mounted on the rotating yoke and a sensor receiver attached to the actuator cover. A feature of actuators in accordance with the principles of this invention is the absence of the additional magnet. A sensor receiver is located in a position in the belt 14 in energy coupling relationship to the magnetized disc magnet rotor 16 as is discussed below.
[0080] FIG. 10 a is view showing a non-circular magnet rotor 56 functioning as the magnetic emitter for the sensor receiver 58 to determine rotor angular position. The sensor 58 is mounted in the belt 14 . The use of a non-circular, for example elliptical, rotor creates a varying distance between the rotor 16 and the sensor receiver 58 whereby the consequent varying magnetic field strength information is utilized to determine angular position information. The non-circular configuration is illustrated by the dimension D 1 being greater than the dimension D 2 .
[0081] FIG. 10 b is another way to provide the varying magnetic flux signal to the sensor 58 . In this embodiment, a portion 60 N and 60 S of each pole is magnetized with a progressively or discretely varying changing magnetic field strength as the magnetic emitter so that the sensor 58 receives the varying flux as a varying signal, the dash lines schematically depicting the variation.
[0082] FIGS. 11 and 12 are views of the belt 14 . The belt material may be of a thermoplastic polyester, such as DuPont Crastin PBT. The central lip 22 spaces the stator assemblies 12 apart to fix the magnetic airgap E as seen in FIG. 8 . Cutout ears 52 are used to clip onto grippers 50 of the stator assemblies 20 . Electrical connections to the stator circuit coil pins 46 are carried out in the areas 62 . If a sensor receiver 58 is mounted in the belt 14 , areas 62 may also be used for its electrical connections. The lip 24 is shown as a continuous element, but it could be discontinuous so long as there are enough portions of the surfaces 24 and 26 to maintain the airgap E. This is illustrated in FIG. 22 in which lip segments 64 are spaced apart.
[0083] FIG. 13 is an exploded view of another embodiment of the present invention 10 where the angular position receiver 58 is mounted to a printed circuit board or leadframe 66 in the cover 48 and a magnetic field emitter 68 is mounted to the end of shaft 18 . Cutout ears 54 mechanically fix the cover 48 to the stator assembly 20 by clipping onto grippers 50 .
Now the Operation of the Actuator Will be Described.
[0084] FIGS. 14 a and 14 b show schematic views of the magnetic poles of the stators 36 a and 36 b and the two pole pairs 70 of rotor 16 in the various operating positions for a 2 pole configuration. The demarcation or transition of the magnetic pole pairs in the rotor 16 is shown at 72 . In FIG. 14 a the rotor 16 is in a ready position relative to the stators 36 a and 36 b , which in an initial ready state are not energized. The ready position is at nominally −45° to the center of the pole 36 a . The rotor 16 is at one end of its useful stroke because of its connection to one extreme position of the user application, e.g. an air valve “fully open”. As seen in FIG. 8 , to operate the actuator the stators 36 a and 36 b will be energized as N and S poles respectively and the stators 36 c and 36 d will be energized as S and N poles respectively. That will cause the rotor to rotate in the direction of the arrow R. This will rotate the shaft 18 to operate the user application. FIG. 14 b shows the position of the rotor 16 after rotation to the other end of its useful stroke, to a final position at nominally +45° to the center of the pole 36 a which is the other extreme position of the application, e.g. an air valve “fully closed”. If the current is removed from the coils, a mechanical means such as a spring may be employed to cause the actuator to return to the first ready position. Typically the application equipment will provide the return spring, although the actuator can have it built-in.
[0085] FIG. 15 is a graph of a 2 pole rotary actuator according to the invention that is, 2 stator poles on each side of the rotor and the rotor having 2 pole pairs. In the graph, the 90° useful stroke has substantially constant torque, and the torque is proportional to the applied current, and in the art is taken as a constant torque actuator.
[0086] FIGS. 16 a - 16 c illustrate a 4 pole configuration 74 of the invention; that is 4 stator poles on each of the stator assemblies 76 a and 76 b on each side of the rotor 78 and the rotor 78 having 4 pole pairs. Although the belt 14 is not shown in this figure, when installed it would define the airgap space E. FIG. 16 b shows the start position for the 4 pole configuration, at nominally −25° from the center of the stator pole, and FIG. 16 c shows the final position at nominally +25° from the center of the stator pole. Typically the 4 pole configuration has a useful stroke for constant torque of approximately 50 to 65 degrees.
[0087] FIG. 17 is a graph of a 4 pole rotary actuator according to the invention. In the graph a 50° useful stroke of constant torque is depicted.
[0088] FIGS. 18 a - 18 c show an asymmetric embodiment 80 of the invention. In the asymmetric embodiment as shown by comparing FIGS. 18 b and 18 c , the stator poles 82 on one side of the rotor 16 are larger than the stator poles 84 on the other side. This results in an axial attraction force on the rotor 40 toward the larger stator poles, which is useful to resist vibration from the user application. Although a 2 pole configuration is shown, the asymmetry can be similarly implemented in a 4 pole configuration.
[0089] FIG. 19 shows another embodiment 90 of the invention in which the rotor 16 has a stator assembly 12 on one side of the airgap E and a passive stator assembly 94 exemplified with a ferromagnetic plate 96 on the other side. This embodiment provides a lower cost actuator but with lower torque. The passive stator can be constructed in any form that has a surface opposite the end faces of the active stator assembly. For example a 2 pole stator without coils could be used. It can appreciated that with a passive stator the airgap dimension E is the distance between the end faces of the active stator poles and the opposite surface of the passive stator. This is shown in FIG. 19 in which the stator assembly 12 is on one side of the rotor 16 and a passive assembly 94 is on the opposite side with the plate 96 serving as the passive stator. The actuator may be attached to an operated device of the type in which the equipment directly drives the application in a rotary movement, or converts the rotation of the shaft to linear motion. FIG. 20 schematically shows the actuator 10 attached to an operated device 100 of the type in which an operated part 102 is directly rotated by the rotation of the shaft 104 , along with a stop mechanism 106 . This would be exemplified by an on-off butterfly air valve.
[0090] Either of the types of equipment, rotary or linear, can be used with the servo actuator version of the invention in which the amount of rotation or linear movement of the equipment and the amount of rotation of the rotor is sensed by the sensor and commands are given by a control system to change the rotational position of the rotor and consequently of the served equipment.
[0091] Examples of rotary control applications using the actuator's output torque are air or exhaust gas recirculation (EGR) control valves, turbocharger variable geometry vane or waste gate control, or throttles utilizing a “butterfly valve” configuration.
[0092] Rotary-to-linear motion may be accomplished via a “crank and slider” mechanism or by a rotating cam with a roller follower producing the linear motion and force. EGR valves of the pintle type and variable geometry turbochargers are examples of automotive applications that can utilize this invention.
[0093] These applications typically have a “home” position, maintained with no power applied to the actuator, and a powered end-of-stroke position where the application is at its maximum value. The invention will be controlled to take a position anywhere along the stroke, and will rapidly move back and forth along the stroke as commanded. A “fail safe” return spring is often incorporated in the application to return the actuator to its home position in the event of a power failure and when power is purposely shut down. In the absence of a return spring, the actuator can hold its end-of-stroke position, at either end, without power being applied.
[0094] FIG. 21 illustrates an integrated version of the invention in which the overmolding 44 of the stator assembly is molded commonly with the belt 14 to create an integrated part 110 that is, the belt and stator assembly as an integrated structure. In this embodiment, the shaft, the rotor and the opposite stator assembly are conveniently assembled to the integrated part 110 . This enables easy assembly and eliminates one dimensional tolerance variation in establishing the airgap space E.
[0095] FIG. 22 illustrates the embodiment of the belt 14 in which the lip is discontinuous as shown by the spaced apart lip segments 64 .
[0096] The foregoing Detailed Description of exemplary and preferred embodiments is presented for purposes of illustration and disclosure in accordance with the requirements of the law. It is not intended to be exhaustive nor to limit the invention to the precise form or forms described, but only to enable others skilled in the art to understand how the invention may be suited for a particular use or implementation. The possibility of modifications and variations will be apparent to practitioners skilled in the art. No limitation is intended by the description of exemplary embodiments which may have included tolerances, feature dimensions, specific operating conditions, engineering specifications, or the like, and which may vary between implementations or with changes to the state of the art, and no limitation should be implied therefrom. This disclosure has been made with respect to the current state of the art, but also contemplates advancements and that adaptations in the future may take into consideration of those advancements, namely in accordance with the then current state of the art. It is intended that the scope of the invention be defined by the Claims as written and equivalents as applicable. Reference to a claim element in the singular is not intended to mean “one and only one” unless explicitly so stated. Moreover, no element, component, nor method or process step in this disclosure is intended to be dedicated to the public regardless of whether the element, component, or step is explicitly recited in the Claims. No claim element herein is to be construed under the provisions of 35 U.S.C. Sec. 112, sixth paragraph, unless the element is expressly recited using the phrase “means for . . . ” and no method or process step herein is to be construed under those provisions unless the step, or steps, are expressly recited using the phrase “comprising step(s) for . . . ”
|
A single phase, rotary electromagnetic actuator comprising first and second stator assemblies, located in oppositely facing spaced apart positions along a common central axis, permits a magnetized disc magnet rotor to rotate about the common axis free of any magnetic attractive forces normally tending to move the disc magnet longitudinally along the axis, or alternatively to be located in a position to create a desired longitudinal attractive force. The entire assembly is maintained in operative positions by a circular belt which provides an inward facing lip on each side of which the stator assemblies are seated and which determines the magnetic airgap spacing for the disc. The invention may be implemented as a servo-actuator by the inclusion of an angular position sensor that uses the actuator rotor as the magnetic field emitter, and a receiver for the magnetic field and its contacts, located in the belt lip.
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FIELD OF THE INVENTION
[0001] The present invention relates to wristbands and headbands.
BACKGROUND OF THE INVENTION
[0002] Referring to FIG. 3 , a conventional wristband 1 is woven from a cotton yarn 2 and a rubber yarn 3 . The cotton yarn 2 provides a soft feeling to a wrist. The rubber yarn 3 provides elasticity necessary for binding the wrist. However, several drawbacks are encountered in the use of the wristband 1 . Firstly, the wristband 1 provides poor ventilation for air. Secondly, the wristband 1 provides poor permeability and absorbency for water. Thirdly, the wristband 1 provides an inadequately soft feeling.
[0003] The present invention is therefore intended to obviate or at least alleviate the problems encountered in prior art.
SUMMARY OF THE INVENTION
[0004] It is an objective of the present invention to provide a band with good ventilation for air.
[0005] It is another objective of the present invention to provide a band with good permeability and absorbency for water.
[0006] It is another objective of the present invention to provide a band with an inadequately soft feeling.
[0007] According to the present invention, a band includes a split compound yarn and a rubber yarn woven together with the split compound yarn. The band is made by means of a process including a step of making the compound yarn, a step of providing the rubber yarn, a step of weaving the compound yarn together with the rubber yarn so as to form the band, and a step of washing the band so as to split the compound yarn.
[0008] Other objects, advantages and novel features of the invention will become more apparent from the following detailed description in conjunction with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present invention will be described via detailed illustration of the preferred embodiment referring to the drawings.
[0010] FIG. 1 is a top view of a wrist wearing a wristband according to the preferred embodiment of the present invention.
[0011] FIG. 2 is simplified view of a machine for making a compound yarn used in the wristband of FIG. 1 .
[0012] FIG. 3 is a top view of a wrist wearing a conventional wristband.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0013] FIG. 1 shows a wrist wearing a wristband 10 according to the preferred embodiment of the present invention. The wristband 10 is woven from a split compound yarn 11 and a rubber yarn 12 .
[0014] To make the wristband 10 , at a first stage, the compound yarn 11 and the rubber yarn 12 are made separately. At a second stage, the compound yarn 11 and the rubber yarn 12 are woven so as to form the wristband 10 . At a final stage 12 , the wristband 10 is dyed and washed so that the compound yarn 11 is split.
[0015] The split compound yarn 11 of the wristband 10 provides advantageous features such as good ventilation for air, good permeability and absorbency for water and an inadequately soft feeling.
[0016] The third stage is closely related to the first stage. That is, the splitting of the compound yarn 11 in the third stage is closely related to the making of the compound yarn 11 in the first stage. Therefore, the first stage will be described in detail.
[0017] FIG. 2 shows a machine for making the compound yarn 11 . The machine includes a first melting and extruding block 20 , a second melting and extruding block 25 , a metering pump 30 , a spinning block 35 , a cooling and curing block 40 , an extending block 50 , a heating and setting block 60 and a reeling block 70 .
[0018] First material 13 , such as nylon is provided to the first melting and extruding block 20 . The first material 13 is molten in the first melting and extruding block 20 . Then, the molten first material 13 is extruded from the first melting and extruding block 20 .
[0019] Second material 14 , such as polyester is provided to the second melting and extruding block 25 . The second material 14 is molten in the second melting and extruding block 25 . Then, the molten second material 14 is extruded from the second melting and extruding block 25 .
[0020] The molten first material 13 and the molten second material 14 are both provided to the metering pump 30 . The molten first material 13 and the molten second material 14 are provided from the metering pump 30 to the spinning block 35 at different predetermined rates.
[0021] In the spinning block 35 , the molten first material 13 and the molten second material 14 are both spun into filaments. The filaments are all provided from the spinning block 35 to the cooling and curing block 40 .
[0022] In the cooling and curing block 40 , the filaments are cooled and cured. Then, the filaments are all provided from the cooling and curing block 40 to the extending block 50 .
[0023] In the extending block 50 , the filaments are compound so as to form a compound yarn. The compound yarn is extended so that its diameter is reduced to a desired value. Thus, the compound yarn becomes the compound yarn 11 . Then, the compound yarn 11 is provided from the extending block 50 to the heating and setting block 60 .
[0024] In the heating and setting block 60 , the compound yarn 11 is heated and set. Then, the compound yarn 11 is provided from the heating and setting block 60 to the reeling block 70 .
[0025] In the reeling block 70 , the compound yarn 11 is reeled.
[0026] To facilitate the splitting of the compound yarn 11 , a chemical step or a mechanical step may be taken in the making of the compound yarn 11 .
[0027] The chemical step is taken in the melting of the first material 13 or the second material 14 . To this end, nucleated agent such as CaSiO 3 , SiO 2 and MoS 2 may be added to the first material 13 or the second material 14 . Thus, the first material 13 crystallizes easier than the second material 14 , or vice versa. Hence, the filaments of the first material 13 are easily split from the filaments of the second material 14 as the wristband 10 is dyed and washed.
[0028] Alternatively, splitting agent such as superfine Teflon may be added to the first material 13 or the second material 14 . Thus, the filaments of the first material 13 are easily split from the filaments of the second material 14 as the wristband 10 is dyed and washed.
[0029] Alternatively, the first material 13 or the second material 14 is made via mixing 20-80% of amorphous polymer with 80-20% of crystal polymer. Thus, the contractibility of the first material 13 is much higher than that of the second material 14 , or vice versa. Hence, the filaments of the first material 13 are easily split from the filaments of the second material 14 as the wristband 10 is dyed and washed in hot water.
[0030] Alternatively, the first material 13 and the second material 14 may be molten at carefully calculated temperatures. Thus, the stickiness of the first material 13 to the second material 14 is low. Hence, the filaments of the first material 13 are easily split from the filaments of the second material 14 as the wristband 10 is dyed and washed.
[0031] The mechanical step is taken in the spinning of the compound yarn 11 . In the mechanical step, the compound yarn 11 reeled at a rate of 3000-8000 meter per minute. Thus, the first material 13 crystallizes at a rate much different from a rate at which the second material 14 crystallizes. Hence, the filaments of the first material 13 are easily split from the filaments of the second material 14 as the wristband 10 is dyed and washed.
[0032] The present invention has been described via detailed illustration of the preferred embodiment. Those skilled in the art can derive variations from the preferred embodiment without departing from the scope of the present invention. Therefore, the preferred embodiment shall not limit the scope of the present invention defined in the claims.
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A band includes a split compound yarn and a rubber yarn woven together with the split compound yarn. The band is made by means of a process including a step of making the compound yarn, a step of providing the rubber yarn, a step of weaving the compound yarn together with the rubber yarn so as to form the band, and a step of washing the band so as to split the compound yarn.
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FIELD OF THE INVENTION
The present invention relates generally to scorekeeping devices, and more particularly is a "talking scorekeeper" for racket and paddle sports. This invention relates generally to Applicant's prior talking scorekeeper for volleyball as disclosed in U.S. Pat. No. 5,574,422, issued Nov. 12, 1996, which is hereby incorporated in its entirety.
BACKGROUND OF THE INVENTION
Racket and paddle sports have huge numbers of recreational participants. Some of the more popular racket and paddle sports include tennis, racquetball, badminton, ping pong, etc.
A common problem encountered by recreational players is losing track of the score. Since there is generally no non-participating scorekeeper, the players themselves have to also track the score. This can lead to many problems, given that the players chief focal point is on the playing of the points themselves. Although players are generally required to announce the score before each serve, confusion can be generated in long rallies, when changing servers, or simply in the course of the game itself. In addition to honest mistakes in the actual score of a game, a less than sportsmanlike player may intentionally misstate the score.
Disagreements in the score are a common cause of discord in recreational paddle and racket games, and can easily lead to arguments and decreased enjoyment of the game. In the worst case, games may be cancelled because of these disagreements.
Because of the expense of having an impartial scorekeeper, that solution is rarely if ever available to the recreational player. Inexpensive score displays are available, but the same problems with confusion of score can arise with these manual devices. It is simply too inconvenient for a player to periodically interrupt the game to update a scoreboard. Similarly, to date there has been no available automated device that has a selling price low enough to make it readily available to the pickup player.
The problem of tracking the score has been addressed by the inventor relative to other sports, e.g. volleyball, in U.S. Pat. No. 5,574,422, the "MULTI-FUNCTIONAL VOLLEYBALL TALKING SCOREKEEPER", issued Nov. 12, 1996. However to date, there is no known equivalent solution for racket and paddle sports.
Accordingly, it is an object of the present invention to provide a means for automatically keeping score of various racket and paddle games.
It is another object of the present invention to provide a device that audibly announces the score before each serve so that errors and incorrect scoring is noticeable by all players.
It is a further object of the present invention to provide a device that allows play to be continuous.
It is a still further object of the present invention to provide a device that has multiple options to allow the user to update the score.
It is another object of the present invention to provide a means to accurately and easily track the score of a game.
SUMMARY OF THE INVENTION
The present invention is an automated scorekeeping device for racket and paddle sports. The device includes a voice recorder that is used to announce the score before each serve of the game. The device further includes optional visual displays. Actuating devices adapted to the equipment of the particular games are provided so that the players can easily operate the scorekeeper while participating in the game. The scorekeeper can be adjusted manually to correct mistakes, and can be used in multiple modes.
An advantage of the present invention is that, prior to each serve, the score is audibly announced so that all players can track the score without visual monitoring. This provides a means to assure accurate and honest control of the score, even when the players themselves are responsible for the scorekeeping.
Another advantage of the present invention is that the score of the game can be kept accurately without interrupting the flow of the game.
A further advantage of the present invention is that the scorekeeper is small, lightweight, and easily installed in existing equipment.
A still further advantage of the present invention is that it is inexpensive to manufacture.
Yet another advantage of the present invention is that it can be utilized by players of all skill levels, and can also be used in organized games by the officials.
These and other objects and advantages of the present invention will become apparent to those skilled in the art in view of the description of the best presently known mode of carrying out the invention as described herein and as illustrated in the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the positioning of the talking scorekeeper for tennis when scoring a point for the server.
FIG. 2 shows the deployment of the talking scorekeeper for tennis when scoring a point for the receiver.
FIG. 3 shows a user making a correction in the score with the talking scorekeeper for tennis.
FIG. 4 shows the user repeating the announcement of the score with the talking scorekeeper for tennis.
FIGS. 4A-D show the secondary functions activated by pressing the triggering means while the racket is in the repeat mode.
FIG. 5 shows the scoreboard for the talking scorekeeper for tennis.
FIG. 6 is an illustration of a manual control panel for the talking scorekeeper for tennis.
FIG. 7 shows the scoreboard of FIG. 5 installed on a net post.
FIG. 8 is a schematic diagram illustrating operation of the talking scorekeeper scoreboard.
FIG. 9 shows a tennis racket used with the talking scorekeeper.
FIG. 10 illustrates a badminton racket used with the talking scorekeeper.
FIG. 11 depicts a racquetball racket used with the talking scorekeeper.
FIG. 12 is a schematic diagram of the circuitry of the racket of the talking scorekeeper.
FIG. 13 shows the physical layout of a tennis racket with self-contained audio scoring.
FIG. 14 shows the physical layout of a racket for a self-contained talking scorekeeper for tennis with both audio and visual scoring.
FIG. 14A is a side view of the device illustrated in FIG. 14.
FIG. 14B is a bottom view of the racket with a battery charging mechanism.
FIG. 14C shows the racket of FIG. 14B in charging mode.
FIG. 14D is a side view of the device illustrated in FIG. 14C.
FIG. 15 shows the physical layout of a talking scorekeeper for tennis with audio scoring only and with remote capability.
FIG. 16 shows the physical layout of a talking scorekeeper for tennis with both audio and visual scoring and with remote capability.
FIG. 16A is a side view of the device illustrated in FIG. 16.
FIG. 17 is a schematic diagram of the talking tennis racket of the present invention.
FIG. 18 illustrates the operation of the talking racket first directional switch.
FIG. 19 illustrates the operation of the talking racket second directional switch.
FIG. 20 shows a remote scoreboard of the talking scorekeeper.
FIG. 20A shows the remote scoreboard of the talking scorekeeper with the function designation face plate removed.
FIG. 21 shows a function designation plate for ping pong.
FIG. 22 shows a function designation plate for volleyball.
FIG. 23 shows a function designation plate for tennis.
FIG. 24 shows a function designation plate for basketball.
FIG. 25 shows a function designation plate for racquetball.
FIG. 26 shows a function designation plate for badminton.
FIG. 27 is a schematic diagram of the scoreboard.
FIG. 28 illustrates a self-contained generator for the racket of the talking scorekeeper for tennis.
FIG. 29 shows a front view of the scoreboard.
FIG. 30 shows adapting means to connect the scoreboard to an external stereo.
FIG. 31 shows the scoreboard connected to an external stereo in such a manner as to retain the stereo functions.
FIG. 32 is a schematic diagram of the scoreboard connected to an external stereo in such a manner as to retain the stereo functions.
FIG. 33 shows a front view of the scoreboard.
FIG. 34 shows adapting means to connect the scoreboard to external stereo speakers.
FIG. 35 shows the scoreboard connected to external speakers.
FIG. 36 is a schematic diagram of the scoreboard connected to external speakers.
FIG. 37 shows a talking scorekeeper with visual display adapted for ping pong.
FIG. 37A is a detail view of the ping pong scorekeeper net bracket.
FIG. 38 shows a talking scorekeeper with visual display adapted for ping pong.
FIG. 38A is a detail view of the ping pong scorekeeper net bracket.
FIG. 39 depicts the first player scoring grid of the ping pong scorekeeper.
FIG. 39A shows the first player scoring grid in position on the ping pong table.
FIG. 40 depicts the second player scoring grid of the ping pong scorekeeper.
FIG. 41 shows a built-in paddle bridge switch on a ping pong paddle.
FIG. 42 illustrates how the paddle bridge switch activates the player scoring grid.
FIG. 43 shows an add-on paddle bridge switch on a ping pong paddle.
FIG. 44 is an overhead view of the ping pong scorekeeper installed on a ping pong table.
FIG. 45 shows an alternate remote score control means for a first player.
FIG. 46 shows an alternate remote score control means for a second player.
FIG. 47 shows a second alternate remote score control means intended for use by a non-participant.
FIG. 48 is a schematic diagram of the ping pong talking scorekeeper.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is a talking scorekeeper that is designed so that it can be adapted to many racket and paddle games. The first embodiment, addressed specifically in FIGS. 1-19, is directed to tennis. The talking scorekeeper includes means to provide a visual display of the score as well as an audio announcement of the score.
The talking scorekeeper for tennis includes a tennis racket 10 and a scoreboard 12. The racket 10 includes a remote control means 101 that is used to control the scoreboard 12. The scoreboard 12 includes a display 14 and a manual control panel 16.
The racket 10 includes orientation sensing means that trigger the scoring functions depending on the orientation of the racket 10 when the remote control means 101 is activated. In the preferred embodiment, when the racket 10 is pointed upward as in FIG. 1, the score for the server is incremented, displayed, and announced. When the racket 10 is extended toward the receiver with the racket face in a vertical orientation as in FIG. 2, the receiver's score is incremented, displayed, and announced. When the racket is pointed downward as in FIG. 3, an erroneous entry is deleted and the score decremented, displayed, and announced. Finally, when the racket is extended with the racket face in a horizontal alignment as in FIG. 4, and the triggering means 102 of the remote 101 is activated, the current score is repeated. If the triggering means is activated twice in rapid succession, the score for the entire playing session to that point is announced. If the racket is rotated to other positions while the repeat announcement is being played, the functions illustrated in FIGS. 4A-D are accomplished. Pointing the racket upward announces the server, downward announces the receiver. While the power on default is the server updating the score, the racket can be programmed so that the receiver keeps score. Rotating the racket 90° in a first direction initiates the tie breaker format scoring, and rotating the racket in a second direction initiates no ad scoring.
The racket 10 accomplishes these scorekeeping functions by means of a racket directional sensing means 103 located in the handle of the racket 10. In the preferred embodiment, the directional sensing means 103 is a plurality of mercury switches, as illustrated in FIG. 18. The arrangement of the mercury switches allows the racket 10 to determine which direction the user is pointing the racket 10. The truth table for the directional sensing means 103 is illustrated in FIG. 18.
FIG. 9 shows the physical construction of the tennis racket 10. Power is supplied by batteries 104 in the handle of the racket 10. No on/off switch is required as the standby current is at 0 when no RF signal is being transmitted. A recessed push button, generally installed in the base of the racket handle, serves as the primary triggering means 102. A transmitter or transceiver (combined transmitter and receiver) 101 allows the racket 10 to communicate with other rackets 10 or with the scoreboard 12. Some form of antenna 105 is required for transmission. FIG. 12 is a schematic diagram of the circuitry of the racket 10.
When a first racket 10 communicates with a second racket 10, a short duration coded signal is used to establish the link between the rackets. The signal updates the microcontroller of the second racket 10 with the current score. The second racket 10 then announces the score through its voice chip 107. These short duration signals require the racket 10 to have far less battery capacity than would for instance a full duration, RF modulated audio score from the transmitting racket.
Also, because of the low number of components and the use of very small SOIC components, the components required will easily fit into the handle of an existing racket. Therefore, retro-fifting existing rackets to give them "talking racket" capability is quite feasible.
If desired, a motion operated generator 106 can be included to charge the batteries 104 in any of the rackets described herein. FIG. 28 illustrates one embodiment of the motion generator 106. The motion generator 106 includes a cylindrical sleeve 1061 with a coil 1062 wrapped around the sleeve 1061. A spring 1063 is affixed to each end of the interior of the sleeve 1061. A permanent magnet 1064 is contained within the sleeve 1061. An electric current is generated by the motion of the magnet 1064 within the sleeve 1061 through the coil 1062. The current is processed through a bridge rectifier 1065 and a filter capacitor 1066, and is then suitable to recharge the batteries of the scorekeeper.
The scoreboard 12 includes a display 14 as shown in FIG. 5. The display 14 includes a server score display 141, a receiver score display 142, a speaker 143, and a means 144 to indicate which player has the advantage following a deuce point. The speaker 143 is used to audibly announce the score.
The display 14 can also be operated by the manual control panel 16 illustrated in FIG. 6. The manual control panel 16 will generally only be used during play if a non-participant is keeping score. In addition to the scoring functions, which function in the same manner as those controlled by the remote 101, the manual control panel 16 includes a volume control and a language select function if the voice chip is programmed in more than one language.
As shown in FIG. 7, the scoreboard 12 can be manufactured as an integral part of a net post 18. In this configuration, the scoreboard would include front and back (the surfaces parallel to the net 20) displays so that both the players can easily see and hear the score. In addition, the scoreboard can optionally include a display with speaker mounted on the side of the net post 18 for the convenience of an audience.
A schematic diagram of the circuitry of the scoreboard 12 is shown in FIG. 8. The microcontroller is controlled by either the remote 101 or the control panel 16. The microcontroller controls the display of the current score on the visual displays 14 of the scoreboard 12. For the audio portion of the scoring, an addressable voice chip is included. The voice chip activates the speakers. Generally, there will be at least two speakers installed in the scoreboard 12. The voice chip is pre-programmed to include all potential scores for both the server and the receiver. A first voice is used for the server's score and a second voice is used for the receiver's score so that there is no chance of mistaking whose score is being announced. For maximum distinguishing of the voices, a male voice and a female voice can be used.
Operation of the racket 10 as illustrated in FIGS. 1-4 is as follows: In FIG. 1, the server has won the first point, and therefore holds the racket upright and activates the triggering means, the push button 102. The scoreboard 12 display 14 will show "15" as the server's score, "0" as the receiver's score, and the audio portion will announce "fifteen love".
When the server depresses the push button 102 with the racket as shown in FIG. 2, the scoreboard will display "15" as both players'score, and will announce audibly "fifteen all" or "fifteen fifteen".
If a mistake is made in the scoring, the user holds the racket as shown in FIG. 3 and activates the push button 102. This will erase the last point entered, and the scoreboard display will be adjusted appropriately, and the new score will be announced. Correction can be repeated as many times as is required. That is, if two points were entered incorrectly, the erase function can be triggered twice. The proper scoring is then input.
To repeat the current score, the racket 10 is positioned as shown in FIG. 4. When the push button 102 is pushed, the current score is audibly announced. If the push button 102 is pushed twice while the racket 10 is in this position, the scoreboard 12 will announce all results for the day, the current score, as well as the scores of any sets played previously in the session. As play continues, the talking scorekeeper continues to update and compile the scoring.
The manual control panel includes a plurality of control buttons 161. In addition to the scoring functions described above, there is a "SELECT LANGUAGE" button that allows multiple languages to be used in the talking scorekeeper. The power on default is the last language used on the machine.
A "RECEIVING PLAYER SCORE KEEPER" button is used if only one of the players has a transmitting racket 10. The power on default mode of the machine is that the server will always update the score. If the "RECEIVING PLAYER SCORE KEEPER" button is activated at the start of play, the talking scorekeeper is alerted that only one player will be keeping score, and adjusts the data entry accordingly.
The "PROGRAM REMOTE" function allows transmitter codes to be stored in the talking scorekeeper to allow remote access.
There are also functions included in the talking scorekeeper to allow players to specify singles or double, what type of scoring is to be used (no add, tiebreakers, etc.), and even the players names to personalize the audio announcements.
FIG. 13 illustrates a second configuration of the racket, a talking racket 10'. This racket includes a built-in voice chip 107 that announces the score through a speaker 108 in the base of the racket handle. The butt cap plate is labelled to remind the user of the racket orientation to accomplish the various scoring activities. The talking racket 10' may optionally include a microphone 108 and a second triggering means 102 located at the top of the racket handle to provide for data input functions as illustrated in FIG. 19. This triggering means 102 is also labelled to remind the user of proper orientation. The talking racket 10' is a self-contained unit that announces the score without the necessity of an independent scoreboard 12.
FIGS. 14 and 14A show a talking racket 10" that includes a visual display as well as the audio announcement. The only additional component required is a small digital display 109 that is mounted on the racket 10". FIGS. 15, 16, and 16A demonstrate talking rackets 10' and 10" that include means to communicate with an opponent's racket or with a remote scoreboard 12. This embodiment requires only the addition of a transceiver 101 and a three-position switch 110. The scoring and programming functions remain unchanged, but the "PROGRAM REMOTE" function allows the scoreboard 12 to be activated. When two talking rackets are being used, the RF signal transceiver codes for each racket are entered the other racket. The codes are entered by setting a first racket switch 110 to the program position. The second racket's transmitter button is activated for approximately one second. The above is repeated to enter the code for the other racket. The codes are retained even after the power is turned off.
FIG. 18 shows the racket 10', 10" position, directional sensing means 103, and the truth table for the rackets. The talking rackets 10', 10" function in the same manner as the transmit only racket 10. FIG. 19 is an equivalent illustration of the programming means controlled by the second motion sensing means. These functions are for initialization of the scorekeeper only.
FIGS. 14B-D illustrate the use of an independent charger 20 adapted to recharge the batteries 104 of the rackets 10, 10', 10". If the charger 20 is to be used, contact elements 201 must be included on the racket. The contact elements 201 of the racket provide a means to establish galvanic contact with the contact elements 202 of the charger 20. The charger 20 is powered by an AC source such as a wall outlet. (The charger technology is known in the art.)
The talking rackets with transceivers provided a convenient means for tennis scorekeeping. The rackets are completely self-contained and require no external devices while in use. The talking rackets can be factory ordered with the owner's name pre-recorded. Also, the player's gender can be specified, i.e. a male voice simulator for a male player and a female voice simulator for a female player.
FIG. 20 illustrates optional modifications of the talking scoreboard 12. The talking scoreboard 12 includes a first mounting mechanism 121 that allows a user to hang the scoreboard 12 on a fence or wall. The scoreboard 12 also includes a second mounting mechanism 122 that is adapted to receive a tripod or a mounting stake to support the scoreboard 12. The scoreboard 12 may also include a multi-pin plug 123. The plug 123 can be used as a connection for wired remote, an input for an external power source, an output to an external speaker system, a serial data output, or any other connection desired by a user. When the scoreboard 12 is being used in a game where the participants switch sides, the scoreboard will rotate score positions with the players. That is, a first player's score will always be on top or right, regardless of his current side. Similarly, the second player's score will always be on the bottom or left.
A single talking scoreboard 12 can be used for numerous sports. Since the scoreboard 12 is controlled by a microprocessor as shown in the schematic in FIG. 27, the microprocessor can be programmed to provide scoring functions according to the scoring rules of various sports. A function designation face plate 124 for the 4×5 push button keypad (see FIG. 20A) of the scoreboard can be changed to provide the necessary labelling for whatever sport is chosen. The function designation plate 124 is labelled with the functions that are programmed into the microprocessor of the scoreboard 12. These function are chosen to handle the various scoring situations provided by the subject game.
To choose a given game, the user activates the talking scorekeeper and presses the GAME SELECT button. The user then enters the number of the desired game, as designated on the appropriate face plate.
FIGS. 21-26 illustrate face plates 124 for an assortment of games that can be programmed into the scoring capabilities of the talking scorekeeper of the present invention. In addition to the racket sports described in detail herein, volleyball and basketball are easily accommodated. These games require different remote mechanisms, as are described in detail in the inventor's prior U.S. Pat. No. 5,574,422. It should also be noted that any button that is activated has a related audio cue. This allows the players to be alerted to a scoreboard function without their having to look at the scoreboard.
FIGS. 29-31 show an adapter 22 that allows the talking scorekeeper to be wired into a portable stereo system 24. The adapter 22 includes a plurality of input/output jacks 221 and connectors 222 that are used to connect to the circuitry of the stereo 24. The appropriate wiring connections are indicated in the schematic shown in FIG. 32. In this wiring configuration, the stereo 24 would be shut off only while the talking scorekeeper announces the score. After the score is announced, the stereo feed would resume through the speakers. The portable stereo 24 must have detachable speakers to accommodate this configuration.
FIGS. 33-35 show another adapter 22' that allows the talking scorekeeper to be wired into a portable stereo system 24. The adapter 22' would only allow the talking scorekeeper to utilize the amplifier and speakers of the stereo. The stereo feed would be disabled in this configuration. The appropriate wiring for this configuration is shown in the schematic in FIG. 36. This configuration does not require detachable speakers.
FIGS. 37 and 37A show the scoreboard 12 of the talking scorekeeper adapted to be mounted on a ping pong table 26. (FIGS. 38 and 38A show the scoreboard with audio capability only.) In the ping pong adaptation, the scoreboard 12 can be constructed integrally to a net bracket 28. The net bracket 28 includes an input jack 281.
As is shown in FIGS. 39 and 40, the talking scorekeeper for ping pong can include a scoring grid 32 embedded in the ends of the ping pong table. The scoring grid includes a first scoring area 322, a second scoring area 323, a first scoring correction area 324, a second scoring correction area 325, and a repeat area 326. To provide the grid with some flexibility to assure solid contacts, the grid 32 is mounted on a cushioning backing, generally foam rubber.
The scoring grid 32 is activated by a contact mechanism 34. The contact mechanism 34 is an electrically conductive wire that is affixed to the paddle 30. The contact mechanism 34 may be embedded in the paddle 30 itself as shown in FIG. 41. Alternatively, as when adding the mechanism to an existing paddle, the contact mechanism 34 can be affixed to a mounting strip 36 that is in turn affixed to the paddle 30, as shown in FIG. 43. Placing the contact mechanism 34 on the end of the paddle 30 eliminates inadvertent scoring contacts when the face of the paddle 30 strikes the grid 32 during play. To make a conductive contact, the paddle 30 must contact the grid 32 at an approximately 90° angle. Players'bodies contacting the grid will have no effect on the scorekeeper, presuming the players are not wearing conductive clothing.
To increment the score, a player simply uses his paddle 30 to make a connection between any two of the wires of the grid 32 in either the first scoring area 322, or the second scoring area 323, depending upon which player or team has won the point. Making this connection causes the circuitry of the scorekeeper to be activated to update the score. (The circuitry of the ping pong scorekeeper is illustrated in the schematic shown in FIG. 48.) If the score needs to be corrected (decremented), the player uses his paddle to make a connection in the correcting areas 324, 325. To repeat the score or to check the proper server, simply press the paddle against the grid 32 in the repeat area 326.
As illustrated in FIGS. 45 and 46, the ping pong paddles 30 can be adapted to contain the transmission means as in the racket 10. For officiated games, a referee remote (described in detail in U.S. Pat. No. 5,574,422) with a red score button, a green score button, and a repeat button can be used to perform the functions of the scoring grid 32.
It is envisioned that the typical deployment of the talking scorekeeper for ping pong will be with the player keeping score using the scoring grid 32. Singles play would be as follows:
After it has been determined who will serve first, that first player presses the first score area 322. The server controls the scorekeeper at all times. The scorekeeper announces "Begin new game, zero serving zero." The voice output used by the scorekeeper is changed from a first voice for the first player serving to a second voice when the second player is serving. The voices alternate after each five points served so as to alternate with the proper server. After each five points, the scorekeeper announces "Rotate serve," followed by the score. The "Rotate serve" announcement precedes the score so that errors in the person serving can be avoided.
To assure that the points are input properly, the scorekeeper emits a short tone immediately preceding announcement of a point won by the server. No tone is emitted for a point won by the receiver. Thus if the server wins the first point, the audio output would be "`tone`, one serving zero." If the receiver then wins the second point, the output would be "one serving one." These audio cues allow the non-scorekeeping player to monitor the score without having to avert his visual focus, thereby improving his concentration on the game.
It should be noted that in practice, the grid 32 will be color coded, so that each player's paddle color matches a side of the grid 32. Further, the receiver's scoring grid is disabled during play so that he does not inadvertently input scored points to the scorekeeper while he is not serving.
The above disclosure is not intended as limiting. Those skilled in the art will readily observe that numerous modifications and alterations of the device may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the restrictions of the appended claims.
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An automated scorekeeping device for racket and paddle sports. The device includes a voice recorder that is used to announce the score before each serve of the game. The device further includes optional visual displays. Actuating devices adapted to the equipment of the particular games are provided so that the players can easily operate the scorekeeper while participating in the game. The scorekeeper can be adjusted manually to correct mistakes, and can be used in multiple modes.
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BACKGROUND OF THE INVENTION
The present invention is directed to a printing press unit for printing on a web of material as the web passes through a printing station formed by an impression roll and a printing cylinder.
In a printing press unit, such as a rotogravure, a printing station is formed between an engraved cylinder and an impression roll. The engraved cylinder, along with the ink applicator and doctor blade are mounted on a carriage or cart which is removable from the press with a second or other cart having a new printing cylinder being inserted to enable changing the printing cylinders. An example of such an arrangement is disclosed in U.S. Pat. No. 3,625,145, whose disclosure is incorporated by reference thereto. One difficulty with this arrangement is that the impression roller is mounted for vertical displacement to insure contact with the printing cylinder of different sizes carried by the same carriage. Thus, when changing printing cylinders of different sizes, problems arise because of the change in the length of the web being fed through the press.
Another difficulty with this known type of printing arrangement is that a large number of extra carriages are required for supporting the various printing cylinders that are to be inserted into the press. This increases the cost of operation because of the expense of each of these carriages or carts due to the fact that the carriage or cart includes not only the doctor blade but the assembly for positioning the doctor blade and an assembly for positioning the ink applicator relative to the printing cylinder and the ink pan. In addition, this large number of extra carts that are necessary in order to have a fast changeover require additional space for storage when not being used.
SUMMARY OF THE INVENTION
The present invention is directed to an improved printing press which, while preferably a rotogravure press, can also be used with an adaptation as a flexo printing press. Each unit of the improved press has a main frame having a pair of side frames spaced apart for each press unit, an impression roll mounted for rotation on a first axis extending between a pair of side frame members, a sub-frame, means mounting the sub-frame on the main frame for pivotal movement around a second axis offset from the first axis, said means for mounting including a lateral movement cf the sub-frame on said second axis and skewing of the second axis relative to the first axis, said sub-frame having chucking means for releasably mounting a printing cylinder for rotation in the sub-frame on a third axis, means for pivoting the sub-frame on said second axis to move a surface of the printing cylinder into printing engagement with a web extending between the printing cylinder and impression roll, inking means for applying printing ink to the surface of the printing cylinder, web guide means including a plurality of rollers mounted to extend between said side frame members for receiving a web entering the press, guiding the web to pass between the impression roll and the printing cylinder and for guiding the web out of the press and means mounted on the sub-frame for rotating at least the printing cylinder. printing cylinder and the ink pan. In addition, this large number of extra carts that are necessary in order to have a fast changeover require additional space for storage when not being used.
SUMMARY OF THE INVENTION
The present invention is directed to an improved printing press which, while preferably a rotogravure press, can also be used with used with an adaptation as a flexo printing press. Each unit of the improved press has a main frame having a pair of side frames spaced apart for each press unit, an impression roll mounted for rotation on a first axis extending between a pair of side frame members, a sub-frame, means mounting the sub-frame on the main frame for pivotal movement around a second axis offset from the first axis, said means for mounting including a lateral movement of the sub-frame on said second axis and skewing of the second axis relative to the first axis, said sub-frame having chucking means for releasably mounting a printing cylinder for rotation in the sub-frame on a third axis, means for pivoting the sub-frame on said second axis to move a surface of the printing cylinder into printing engagement with a web extending between the printing cylinder and impression roll, inking means for applying printing ink to the surface of the printing cylinder, web guide means including a plurality of rollers mounted to extend between said side frame members for receiving a web entering the press, guiding the web to pass between the impression roll and the printing cylinder and for guiding the web out of the press and means mounted on the sub-frame for rotating at least the printing cylinder.
Preferably, the inking means includes an applicator mounted on the sub-frame, a doctor blade being mounted by a positioning assembly on the sub-frame and an ink pan which is mounted under the printing roll by an arm which is mounted for pivotal movement on one of the side frame members around a vertical axis and is adjusted along the vertical axis so that the side arm can be used to remove the printing cylinder by being raised so that the ink pan supports the cylinder, releasing the cylinder from the chuck means, then lowering the cylinder and swinging the arm in a pivotal movement to remove the cylinder from the press, wherein the pan and cylinder can be removed and a new pan and cylinder are inserted. Then, the arm is pivoted underneath the position for the cylinder, raised to present the new cylinder on the axis to be gripped by the chucking means and the pan is then lowered to the operational position.
If a flexo printing arrangement is used, the arm can be used for positioning a second sub-frame which has an ink pan, an inking roll and a transfer roll. The frame of the press is modified to provide a pivot mounting and to hold the transfer roll in the desired contact with the printing cylinder. When changing the printing cylinder, the transfer arm is first used to remove the sub-frame having the ink pan, inking roll and transfer roll, and then is provided with a pan and moved into a position for supporting the cylinder as it is being removed.
The press unit of the invention has many advantages over the previously known presses, such as the impression roll being in a substantially fixed position so that the length of the web entering the printing station remains the same regardless of changes of the printing cylinder. The sub-frame can be moved vertically upward to apply the desired pressure of the printing cylinder on the web at the printing station that is passing between the printing cylinder and the impression roll. In addition, the sub-frame's pivoting allows changing the diameter of the printing rolls without changing the length of the web entering into and removed from the printing station because the position of the impression roll remains the same. The sub-frame can also be moved laterally for purposes of registration of the web and can be skewed on the second axis as desired.
Another advantage of applicants' invention, particularly when used in a rotogravure press, is that when changing the color and printing cylinder, only the printing cylinder, ink pan, the doctor blade and applicator are removed while the positioning assemblies for supporting the doctor blade and the ink applicator remain in the press. A third improvement is that the rotogravure cylinder and pan are removed together with the pan supporting the cylinder during the step of replacement.
Other advantages and features of the invention will be readily apparent from the following description of the preferred embodiments, the drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view schematically showing several printing stations or unit in a printing apparatus in accordance with the present invention;
FIG. 2 is an enlarged partial side view with portions broken away illustrating the position of a printing cylinder and impression roll and also showing a support for supporting the ink pan in various positions, including a partially pivoted out position during removal of the pan and cylinder;
FIG. 3 is a cross sectional view taken along the lines III--III of FIG. 2;
FIG. 4 is a diagrammatic plan view showing offsetting of the sub-frame and connection of the drive shaft from one press unit to another;
FIG. 5 is a diagrammatic plan view similar to FIG. 4 showing the ink pan and printing cylinder as it is being partially moved out during an exchange of the pan and cylinder;
FIG. 6 is a diagrammatic plan view similar to FIG. 5 with the pan and cylinder in the completely removed position for exchanging the pan and cylinder;
FIG. 7 is a diagrammatic plan view similar to FIGS. 4, 5 and 6 showing a modification of the arm arrangement with an intermediate position shown in dotted lines and the final removed position shown in bold lines;
FIG. 8 is a diagrammatic plan view of the sub-frame schematically showing the means for moving the frame laterally on a second axis, the means for skewing the second axis and the chucking means;
FIG. 9 is a partial cross sectional view taken on line IX--IX of FIG. 8;
FIG. 10 is a partial cross sectional view taken on line X--X of FIG. 8;
FIG. 11 is a cross sectional view of the ink pan and the pan mount in detail;
FIG. 12 is a partial plan view of the unit showing the frame for the pan mount;
FIG. 13 is a schematic side view with portions broken away illustrating the flexo option for attaching a flexo printing arrangement in the unit; and
FIG. 14 is a partial view taken on line XIV--XIV of FIG. 13.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The principles of the present invention are particularly useful when incorporated in a printing system, generally indicated at 100, which has a plurality of printing units, generally indicated at 11, 11a and 11b, arranged one after another for acting on a web 12 of material being fed through the units. Each of the units 11 has a printing station formed by a printing cylinder 15 coacting with an impression roller or cylinder 16, through which the web 12 passes.
In addition, each of the units has guide means comprising a plurality of rolls, which guide the web 12 through the printing station and into a drying chamber 18 that is positioned above the printing cylinder 15. As illustrated, each of the guide means includes a plurality of rolls 20-36. As illustrated in the unit 11, the web 12 enters the unit 11 and passes over a roll 20 around an adjustable take-up roll 21 and goes to a guide roll 22. From the guide roll 22, it passes between the impression roll 16 and the printing cylinder 15 and then goes to a guide roll 23. From the guide roll 23, it goes to the guide roll 24, which is in the drying chamber, back to a guide roll 25 to guide roll 26, 27, 28 and then to guide roll 29. This arrangement is for printing side down and the printing cylinder 15 is rotated in a counterclockwise direction, as indicated by the arrow.
In the next station or unit 11a, the guide rolls are illustrated for guiding in a printing side up and, thus, from the roll 29 of station 11, the web 12 goes to roll 20a to the take-up roll 21a to the guide roll 32a, then to a guide roll 33a. From the guide roll 33a, the web then goes to a guide roll 31b of the unit 11b, then to roll 30b, back to roll 36a for guidance between the printing cylinder 15a and impression roller 16a. From the printing cylinder 15a, the web then goes to the roller 22a, roller 34a, roller 24a to roller 23a and, finally, to roller 35a, where the web then leaves the unit or press 11a and goes to press 11b. In press 11a, the printing cylinder 15a is rotating in the clockwise direction, as illustrated by the arrow.
Each of the printing units 11 has a main frame comprising two main frame members, such as 40 and 41 illustrated in FIG. 3. As mentioned hereinabove, the impression roll is mounted for rotation in the main frame on a first axis 316 and extends between the two frame members 40 and 41. The printing cylinder 15 is mounted in a sub-frame, generally indicated at 50 in FIG. 2, and, as best illustrated in FIG. 8, comprises an axle 51, a first plate 52, a second plate 53, a third plate 54 and a fourth plate 55. Each of the plates 52, 53, 54 and 55 at one end are rigidly connected to the axle 51 to rotate therewith. The axle 51 has a length greater than the spacing between the side frame members 40 and 41 and is mounted in the main frame so that the first and second plates 52 and 53 extend on opposite sides of the side frame member 40, while the third and fourth plates 54 and 55 extend on opposite sides of the side frame member 41. As illustrated, the sub-frame 50, which is also a floor plate assembly, is mounted in the side frame members 40 and 41 by bearing means, such as 56 and 57. To allow for lateral alignment, means 58 are provided for laterally shifting the axle 51 on a second axis in the bearings 56 and 57. The bearing 56 is mounted for pivotal movement by a pin 56a, as illustrated in FIG. 9, and the bearing means 57 can be shifted by a threaded arrangement, such as 57a, as illustrated in FIG. 10, so that the axis of the axle 51 can be shifted about a pivot point formed by the bearing 56. This will cause skewing, which enables obtaining the desired alignment of the web during the printing operation along with the desired lateral offset. The skewing and lateral offset are done in a conventional manner, the exception being that in known printing presses, usually the axis of rotation of the printing cylinder is skewed and laterally offset instead of an entire sub-frame.
As illustrated in FIG. 8, chucking means, which is generally indicated at 60, includes a fixed axle 61, which has a conical head or end 62, is mounted in a fixed fashion for rotation in the third and fourth plates 54 and 55 and is connected to a gear box 63 for a drive shaft, such as 64. On the opposite side is a movable axle or shaft 65, which is mounted both for rotational movement and for axial movement in the plates 52 and 53. The movable axle 65 also has a conical head or end 66. The chucking means 60 engages the cylinder 15 by having the conical or tapering end 62 and 66 engaged in conical or tapering bores 67 and 68, respectively, of the cylinder 15.
In order to complete the chucking means, a clamping arrangement 70 is provided and acts on the movable shaft 65 with a toggle arrangement 71. As illustrated, a shaft 72 of an actuator 73 shifts a link of the toggle. Such an arrangement of the toggle allows developing a very high clamping force. It is noted that the shaft 61, as mentioned before, is fixed in bearings on the plates 54 and 55 and extends through an opening in the side frame member 41. The shaft 65 also extends through a large opening in the member 40 and is mounted in bearings which both allow rotation and axial sifting. It should be noted that the openings in both the frames 41 and 40 are enlarged to allow movement of the axles 61 and 65 with the sub-frame 50 as it pivots around the second axis of the axle 51.
As best illustrated in FIGS. 2 and 3, means formed by pneumatic actuators 75, 75a are provided for pivoting the sub-frame 50 about the second axis. These means are illustrated as comprising a cylinder 75, which is pivotably mounted on a side member 40 and is connected to the second plate 53 while the other actuator 75a is connected to the side frame 41 and is coupled to the third plate 54. As illustrated in FIG. 2, the chucking means 60 chucks the cylinder 15 on a third axis 69, which extends parallel to the second axis of the axle 51. This axis 69 is the same, regardless of the size of the cylinder. Thus, if a 20-inch diameter cylinder 15 is utilized, as shown in bold lines in FIG. 2, the frame 50 is moved to bring the surface of the cylinder in engagement with the web. However, if a 10-inch diameter printing cylinder is used, such as the cylinder 15', then the frame 50 is moved to shift the second axis to the position 69' with the surface engaging the web at the printing station. As can be readily seen, a changing of the size of the printing cylinder between 15 and 15' will not cause any change in the path of the web 12 and require any special adjustments of the web.
As illustrated in FIG. 2, in addition to the chucking means, the frames are provided in a positioning assembly, generally indicated at 79, which is pivotably mounted on the inner two plates 53 and 54, on the right side of the printing cylinder 15. As illustrated in FIG. 2, a second positioning assembly, generally indicated at 80, is pivotably mounted on the left side of the cylinder 15. In FIG. 2, the assembly 79 on the right side of the cylinder 15 has a doctor blade holder 81 releasably connected thereto, while the second assembly 80 supports an ink applicator 82 that is also releasably held thereon. As mentioned above, the openings for the shafts or axles of the chucking means are sufficiently big enough in the side frames that the doctor blade holder can be removed therethrough when the doctor blade holder 81 is released from the positioning assembly 79. In a similar manner, the ink applicator 82 can be released and withdrawn through this opening.
It also should be pointed out that, as illustrated in FIG. 2, the cylinder 15 is rotating in a counterclockwise direction. If the cylinder was being rotated in a clockwise direction, then the doctor blade holder 81 would be releasably mounted on the positioning assembly 80, while the ink applicator 82 would be releasably mounted on the positioning assembly 79.
Referring to FIGS. 2, 3, 11 and 12, an ink pan 85 is supported beneath the printing cylinder 15 by an arm 86. The arm 86, at a free end, is pivotably connected by a pivotable connection 87 to a pan frame support 88 (see FIG. 12). At the opposite end, the arm 86 is connected to an arm mounting means, generally indicated at 90 in FIGS. 2, 11 and 12, to the side frame member 40. The arm mounting means 90, as illustrated in FIGS. 2 and 11, includes a threaded shaft 91, which is driven by a motor 92 mounted on the side frame member 40. An upper end of the threaded shaft 90 is supported by a bearing block 93 on the side frame. Threaded nuts or sleeves 94 and 95 are threaded on the shaft 91, as best illustrated in FIG. 11. The threaded sleeve 94 is connected to a portion 96 of a carriage 97, which also has a portion 98 receiving the sleeve nut 95. The arm 86, as illustrated in FIG. 14, has a bottom plate 86a, which is received on the bottom sleeve nut 94 and is attached to the plate forming the arm 86. At an upper end, a hub 86b is received on the sleeve nut 95 (FIG. 11) and spaced from the portion 96 by a thrust bearing 99. As best illustrated in FIG. 12, the carriage 97 rides on track members 100, which are secured on an end of the side frame 40 and to facilitate the vertical movement on the track members 100 is provided with a plurality of rollers, such as 101. Thus, with rotation of the screw 91, which lies on a vertical axis parallel to the track formed by the track members 100, the carriage 97 and arm 86 move in a vertical direction or axis. The sleeve nuts 94 and 95 form bearings to allow pivotable movement of the arm 86 around the vertical axis.
The frame 88 has an open configuration with a portion or back member 102 (FIG. 12) which has a pin that is received in a socket at the end of the arm 86 to form the pivotable connection 87. The frame also has two parallel side portions 103 and 104, which terminate approximately half the distance from the back member 102 and has a front or forward portion 105 which extends parallel to the back member 102 and is connected by a slanting member 106 to the end of the side frame portion 103 and 107 to the side portion 104. The front portion 105 engages a stop 108 of the sub-frame 50 to orient the frame and pan 85.
The ink pan 85 (FIG. 11) has a curved configuration with a portion forming a drain line 110 connected to one side, which portion 110 can be connected to a hose 111 for a return to an ink sump for the printing device. The drain line 110, as mentioned, forms a portion of the pan 85 and the pan 85 is provided with pads 114, 114 which are composed of a material, such as nylon, and will engage the printing surface of the cylinder 15 when the pan 85 is raised into contact with the cylinder to support the cylinder. The pan 85, as mentioned hereinabove, is removable from the frame 88 and, as illustrated, the pan is provided with three U-shaped feet, such as 115 and 116. The feet, such as 115 are caught on pins or hooks to be held on the frame while the foot 116 rests on a yieldable pin 117 which, when pushed to a downward position, actuates a limit switch, such as 118, to indicate that the pan 85 is in contact with the surfaces of the cylinder 15 and cannot be moved any further in an upward vertical direction.
As illustrated in FIG. 4, each of the gear boxes 63 is connected by a drive shaft 64 to the next adjacent gear box or either the following or the preceding press unit. These connections are formed by universal joints 120 so that when the sub-frame 50 is shifted laterally, the gear box 63 moves with the sub-frame and the joints 120 compensate for the various shifting. Thus, movement of the sub-frame 50 in the direction of the double-arrow 121 is compensated by these joints 120.
FIGS. 4, 5 and 6 also diagrammatically illustrate the arm 86, the pivot connection 87, along with the frame 88 that supports the ink pan 85. These portions are all illustrated in FIGS. 4, 5 and 6. While in the position illustrated in FIG. 4, the mounting means 90 is raised until the ink pan 85 engages the surface of the printing cylinder 15. Then, the chucking means is released to disengage the cylinder 15, which is now resting on the pads 114 of the ink pan 85. In the next step, the mounting means 90 is actuated to lower the arm 86, the frame 88 and the ink pan 86 with the cylinder 15 to a position sufficiently low enough, as illustrated in chain lines in FIG. 2, so that the arm can be pivoted around the vertical axis formed by the mounting means 90 to an intermediate position, such as illustrated in FIG. 5 in bold lines. It is noted that, because of the pivot connection 87, the frame 88 supporting the pan 85 will pivot to a position so that there is adequate clearance between the unit and the next following unit. Continued pivoting brings the arm 86, the pan 85 and frame 88 to the position illustrated in FIG. 6, wherein the pan, along with the cylinder can be removed from the frame 88 and replaced by a new ink pan containing a new cylinder. At the same time, as mentioned above, the doctor blade holder and the ink applicator are removed from their support or positioning assemblies.
To insert the new cylinder and new pan, the next step is to swing the arm to the position, such as illustrated in FIG. 4, wherein the frame, such as the frame member 105, will engage the stop member 108 to insure that the frame and the pan supported thereon have the desired orientation. Then, the mounting means 90 is raised until the new cylinder and the pan contacts the impression roll 16, which causes actuation of the switch 118 to stop the vertical movement. Then, the sub-frame 50 is positioned so that the third axis of the chucking means 60 is aligned with the cylinder, and the movable shaft 65 of the chucking means is moved to cause the clamping or chucking of the cylinder. Following this action, the arm mounting means 90 is lowered to position the inking pan in the desired relationship relative to the cylinder, such as illustrated in FIG. 2. Prior to inserting the new cylinder, the new ink applicator and the new doctor blade holder can be inserted in their respective positioning assemblies 79 and 80.
In the above-described description, the arm 86 has two pivotable connections, one to the frame 88 and the other one formed by the connection to the arm mounting means 90. FIG. 7 diagrammatically shows a modification wherein an arm 86' has a fixed connection 87' to the frame 88 so that the frame is always in the same relationship to the arm as it is moved from a position beneath the third axis of the chucking means 60 to the outward position shown in bold lines. While this requires additional space for clearance between the units, it does have the advantage of having the proper orientation for the cylinder received in the pan as a new cylinder is being moved into a position for being grasped by the chucking means 60.
It is sometimes desirable to be able to convert the rotogravure unit 11 into a unit which can handle flexo printing. To accomplish this, as illustrated in FIGS. 13 and 14, the impression roller is provided with a flexo impression roller 216 that is mounted for rotation on a first axis 216'. The previous printing cylinder is replaced by a flexo printing cylinder 215, which is held by the chucking means in the sub-frame 50. Since, in a flexo printing, only a kiss-type contact is maintained, the flexo printing roll 215 has a gear which meshes with a gear on the shaft of the impression roll 216 so that both rolls move at the same peripheral surface speed. When positioning the roller, such as 215, in the sub-frame 50, an ink pan arrangement on the arm 86 is utilized.
After positioning the flexo printing roller 215, a second sub-frame 250 having a pair of side frames 251 spaced apart a distance to enable them to be inserted between the inner two plates 53 and 54. Adjacent the bottom portion of the sub-frame 250, a plate 253 extends between the two side frames 251. Each of the side frames 251 is provided with a notch 254 for receiving a pivot pin 255, which is mounted on the inner surface of each of the side frames 40a and 41a of the main frame for the modified press unit 11'.
Mounted between the two side frames 251 is an inking pan 260 which rotatably supports and inking roller 261 that has its own separate drive unit or motor. The inking pan 260 is mounted for vertical adjustment relative to the second frame 250 by a rack-and-pinion arrangement, including the rack 262 and pinions 263, which pinions are mounted on a shaft 264 that is rotated by a motor 265 and is mounted on the plate 253. Mounted for rotation in the frame 250 is a transfer or anilox roller 270 (FIG. 13), which has a gear that will mesh with a gear on the printing roller 215 so that when a kissing surface contact is therebetween, the rollers will be driven at the same surface speed.
To pivot the frame 250 to bring the roller 270 into surface contact with the printing roller 215 and to engage the meshing gears, an actuator 271 is mounted on each of the side frames 40a and 40b and has a ram 272 with a pin 273 engaged in a catch on each of the side frames 251. To control the amount of pressure between the roll 270 and the roll 215, an adjustable stop 275 is provided. The sub-frame 250 is brought into position by the pivot arm 86, which has a socket to receive a pin 280 on the plate 253, as illustrated in FIGS. 13 and 14, and then the pivot arm is lowered to be moved out of engagement. During operation, contact between the printing roll or cylinder 215 and the impression roller 216 is controlled by the cylinder or actuator 75 by raising and lowering-the sub-frame 50. The pivoting of the second sub-frame 250 on the pivots points 255 controls the contact between the roller 270 and the cylinder 215 Raising and lowering of the ink
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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A printing press unit for a printing press system which has a main frame with an impression roller mounted for rotation on a first axis characterized by a sub-frame being mounted for pivotal movement around a second axis and supporting a printing cylinder which will be moved into contact with the web passing between the impression roll and the cylinder. The sub-frame can be laterally adjusted along the second axis and the second axis can be skewed as necessary for purposes of registration of the web during a printing process. For a rotogravure printing, the ink applicator and doctor blade holder are both releasably mounted on positoning assemblies which are provided on the sub-frame. In addition, an ink pad is held beneath the printing cylinder by an arm, which can is pivotably connected to the main frame and can be vertically raised and lowered so that the pan receives the cylinder as it is released from the sub-frame, then lowers the cylinder to a level to clear the portions of the press and is then pivoted out of the press for exchange. During this exchange, the ink applicator and doctor blade holder can also be quickly removed. The press can also be modified to receive an inking and transfer roller for a flexo printing process as the printing roller is mounted in the first sub-frame.
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BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for debarking tree sections.
There is a substantial need for fuller utilization of pulp wood in view of increasing demand and resource limitations. At present, processing losses may account for up to 70% of a tree cut. To a substantial degree, these losses have resulted from the inability of existing equipment to debark both relatively large logs and relatively smaller limb sections or treetops. The tendency, therefore, was to employ log debarking equipment and to discard the smaller tree limb portions. In the pulp and paper industry, efficient bark removal is especially important because only small quantities of bark can be tolerated in the pump mixture. For example, approximately 4% is the upper limit of bark content that will be accepted by both pulp mills.
SUMMARY OF THE INVENTION
It is a general object of the invention to provide an improved debarking method and apparatus.
Another object of the invention is to provide a debarking apparatus and method which is capable of debarking both logs and relatively smaller tree limb and top sections.
A further object of the invention is to provide a substantially continuous debarking method and apparatus capable of processing tree sections of various sizes.
A further object of the invention is to provide a debarking apparatus and method which is independent of the size and shape of the tree segments to be debarked.
These and other objects and advantages of the instant invention will become more apparent from the detailed description thereof taken with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the apparatus according to the invention;
FIG. 2 is a sectional view of a portion of the apparatus;
FIG. 3 is a view taken along lines 3--3 of FIG. 1;
FIG. 4 is a view taken along lines 4--4 of FIG. 2;
FIG. 5 is an exploded perspective view of a portion of the apparatus;
FIG. 6 is a fragmentary view of the drive assembly for one of the cylindrical sections illustrated in FIG. 5;
FIG. 7 is a view taken along lines 7--7 of FIG. 1; and
FIG. 8 is an enlarged view of a portion of the recycle assembly of the apparatus shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows the apparatus of the invention generally to include a first plurality of cylindrical sections 11a, 11b, 11c, and 11d and interposed larger diameter cylindrical sections 12a, 12b, and 12c. As will be discussed more fully hereinbelow, each of the cylindrical sections 11a-11d and 12a-12c are independently mounted for rotation on a suitable support which may comprise, for example, a flat bed trailer 14 with the sections 11a-11d being rotatable in a first direction and the sections 12a-12c being rotatable in an opposite direction. In addition, the sections 11a-11d and 12a-12c are each open-ended and interface one with the other to provide a continuous flow path therethrough for logs 16 and impact objects 17. Also, as will be discussed more fully hereinbelow, the smaller diameter cylindrical sections 11a-11d are generally coaxial with each other while the cylindrical sections rotate about axes which are at a higher elevation than those of sections 12a-12c so that as seen in FIGS. 1 and 2 the lower periphery of the cylindrical sections 11a-11d are elevated above the lower peripheral portions of the larger diameter sections 12a-12c. As a result, a log 16 being debarked will be supported by the smaller diameter sections 11a-11d while the impact objects 17 will tend to fall toward the lower ends of the larger diameter sections 12a-12c.
As indicated above, the cylindrical sections 11a-11d and 12a-12c are open-ended and interfaced with each other to provide a continuous flow path through the apparatus. In addition, an infeed section 18 is disposed at one end of the apparatus and includes a frusto-conical member 20, a cylindrical portion 21 formed of a foraminous material and which couples the large diameter end of the member 21 to the open end of the cylindrical section 11a and a flanged nose ring 22 mounted on the small diameter end of member 20. Similarly, a discharge section 19 is disposed at the opposite end of the apparatus and includes a frusto-conical member 23 whose large diameter end is connected to the last rotatable cylindrical section 11d through a cylindrical section 24 formed of axially extending spaced apart bars 25 and a nose ring 26 affixed to the small diameter end of member 23. The cylindrical portion 21 of the infeed section 18 interfaces with the first rotating section 11a and has substantially the same diameter. The perforated or screenlike material of which portion 21 is formed permits small dirt particles and gravel to pass therethrough. Similarly, the cylindrical outlet portion 24 of discharge section 19 is substantially the same diameter and interfaces with the cylinder section 11d. The spaced apart bars 25 of which portion 24 is formed permits the discharge of the impact objects 17 into a recycling system 32 as will be described below. As will also be described more fully below, the infeed section 18 and the discharge section 19 are rotated in the same direction as the cylindrical sections 11a-11d.
An air evacuation system 28 is shown in FIGS. 1 and 3 to be coupled to each of the smaller diameter cylindrical sections 11b, 11c and 11d for providing an air stream to promote the discharge of bark and foreign material from the assembly. The air delivery system 29 includes a duct system 29 coupled to the gap between the unequal diameter cylindrical sections 11a-11d and 12a-12c and an outlet coupled to a suction fan 30. A suitable prime mover, not shown, but of a type well known in the art drives fan 30 and also operates the rotational drives for cylindrical sections 11a-11d, 12a-12c, a material handling system 32 for receiving the impact objects 17 as they discharge from the cylindrical section 11d and for recycling the same to the cylindrical section 11a.
Cylindrical sections 11a-11d are identical to each other and the larger diameter cylindrical sections 12a-12c are also identical to each other. For the sake of brevity only sections 11c and 12c will be discussed in detail in relation to FIGS. 2, 4 and 5. More specifically, the cylindrical section 11c comprises an outer metallic, cylindrical shell 35 and axial flanges 36a and 36b disposed at each of the opposite ends. In addition, a lining 37 formed of an elastomeric material, such as rubber is disposed on the interior surface of the shell 35. A plurality of axially extending vanes 38 may be formed on the inner surface of liner 35 to impart rotational motion to the logs 16 or wood sections which may be disposed therein.
The larger diameter cylindrical section 12c also includes an outer cylindrical shell 38 and end flanges 39a and 39b which extend outwardly from the outer surface of the shell 38. A liner 40 is also disposed on the interior surface of shell 38 and is formed of an elastomeric material, such as rubber. The liner 40 is formed with an inwardly extending flange 41 at each end and a plurality of spaced apart partition walls 42 extend axially along the inner surface of liner 40 and between the end flanges 41 to define a plurality of pockets 43 for circulating the impact objects 17 upwardly and for releasing the same for impacting the logs 16 or tree sections being debarked. The elastomeric liners 37 and 40 are provided to reduce noise in the debarking apparatus, to minimize wear and to promote the activity of the impact objects 17 as they resiliently engage and rebound from said liners.
As seen in FIG. 5, the cylindrical section 11c is mounted for counterclockwise rotation as viewed in a downstream direction and about a generally horizontal axis by means of a friction wheel drive assembly 47 which engaged the outer surface of the shell 40. In a similar manner, the section 12b is mounted for generally clockwise rotation as viewed in a downstream direction about a generally horizontal axis by means of a friction drive assembly 48 which engages the outer surface of shell 35 and between the flanges 36a and 36b. It will be appreciated that friction drive assemblies are provided for each of the sections 11a-11d and 12a-12c and each may be driven by a common drive assembly or the cylindrical sections may each be driven by an individual motive means to simplify the coupling. In addition, the friction wheel drives may take any convenient form. For example, the drive roller assembly 47 is shown in FIG. 6 to include a pair of frusto-conical friction rollers 47a and 47b having mating end surfaces 48a and 48b which are in resilient engagement with each other. A shaft 49a extends through and is journaled for rotation in a suitable bearing 50a mounted on a bearing support 51 which in turn is supported on trailer 14. The opposite end of shaft 49a is coupled to a rotary hydraulic motor 52. Similarly, a shaft 49b extends from roller 47b through a second bearing mounted on support 51. As those skilled in the art will appreciate, the motor 52 is coupled to a source of fluid pressure through coupling pipes 54 and 55. The peripheral surfaces of the rollers 47a and 47b will also resiliently engage the inside surfaces of the flanges 36a and 36b of cylindrical section 35. Accordingly, when suitable fluid pressure is supplied to motor 52 through coupling conduits 54 and 55, the roller 47b will rotate thereby also rotating the roller 47a and the two will rotate the cylindrical section 35. It will also be appreciated that suitable idler rollers 56 may engage the other sides and the upper ends of the sections 11a-11d and 12a-12c to maintain proper alignment and that rollers 56 may be supported on trailer 14 by a suitable support, not shown. The infeed and discharge assemblies 18 and 19 are similarly rotated by drive assemblies 60 which engage the nose rings 22 and 26 and a plurality of suitable idle rollers 61 may also be provided.
Referring now to FIG. 3, it can be seen that the rotational axis 70 of the small diameter section 11c is offset upwardly and to the right of the rotational axis 71 of the larger diameter section 12b. A continuation of the plane 72 which intersects the rotational axes 70 and 71 of the cylindrical sections 11c and 12b also intersects a line 73 which is substantially tangent to the two sections. Each of the cylindrical sections 11a-11d and 12a-12c are all tilted about a series of axes parallel to the line 72 shown in FIG. 3 such that their upper ends move forwardly and their lower ends move rearwardly relative to the direction of flow of the material through the apparatus. As a result, the sections 11a-11d and 12a-12c each rotates about parallel, but not coincident axes.
The points of greatest forward tilt of the sections 11b and 11c will be 90° clockwise around its respective rotational axis and from the tangent line 73, or in other words, the point 74 for section 11c and 75 for section 12b, respectively. Similarly, the points of greatest rearward displacement of cylindrical sections 11c and 12b are points 76 and 77, respectively. The inlet assembly 18 and the outlet assembly 19 which are respectively coaxial with the smaller diameter sections 11a and 11d and are similarly oriented. While the degree of forward tilt of the cylindrical sections 11a-11d and 12a-12c and of the inlet and outlet assemblies 18 and 19 will be a matter of design preferance, a tilt of about 7°-10° along lines 74-76 and 75-77 will provide the desired rate of migration of log or tree sections and impacting objects through the apparatus.
As indicated above, the cylindrical discharge section 24 is composed of a plurality of axially extending, spaced apart bars 25 which extend between a flange 80 integral with the large diameter end of frusto-conical member 23 and a ring 81 which defines the upstream end of section 24 and which interfaces with the open end of cylindrical section 11d. Disposed below the section 24 as seen in FIG. 7, is an impact object receptacle 83 consisting of generally vertical side walls 84 and upwardly inclined deflector plates 85 for directing impact objects 17 which fall between the bars 25 downwardly into the receptacle 83. The bottom of receptacle 83 is defined by a tiltable bottom pan 87 which may be selectively pivoted about pin 88 between a position shown by broken lines in FIG. 7 wherein the same closes the lower end of receptacle 83 and a position shown by full lines wherein it is inclined downwardly for directing the impact objects to the recycle assembly 32.
As seen in FIGS. 2, 7 and 8 the recycle assembly 32 includes an endless belt 90 which extends around rollers 91, 92 and 93, one of which may be a drive roller and the other two idlers. For example, a hydraulic motor 94 is shown in FIG. 7 to be coupled for driving roller 93. It will be appreciated that the rollers 91, 92 and 93 may be suitably journaled for rotation on trailer 14 by means not shown and that hydraulic motor 94 may be coupled to a suitable pump, not shown, and which is suitably driven from the prime mover (not shown) in a manner well known in the art. The belt 90 also passes around a recycle wheel 95 which has a center drum 96 around which the belt 90 extends and a pair of side flanges 97 which engage the sides of said belt. The recycle wheel 95 is journaled for rotation by belt 90 so that its peripheral speed is substantially the same as the linear speed of belt 90.
It will be appreciated with reference to FIG. 7 that when the pan 87 is in its inclined position, the impact objects 17 which migrate through the apparatus and from the cylindrical section 11d to the discharge portion 24, will fall through the bars 25, slide down the pan 87 and unto the upper surface of belt 90, a deflector 98 at the far side of belt 90 relative to pan 87 prevents the objects 17 from rolling off of said belt.
Referring again to FIG. 8, the impact objects 17 are shown to be carried along the upper surface of the belt 90 and moved into engagement with the drum 93 where they are held in resilient engagement therewith as the wheel 95 rotates and until the objects 17 approach the upper extremity of the drum 96. At the point where the drum and the belt 90 part, the rotation of the wheel 95 carries the objects 17 along the clockwise direction as viewed in FIG. 8 until they move onto a downwardly inclined deflector 99 which extends into the open end of the first large diameter section 12a.
The air evacuation system 28 is shown in FIGS. 1 and 3 to include a duct 29 consisting of a main section 100 which extends from the fan 30 in a direction generally parallel to the rotational axes of the cylindrical segments 11a-11d and 12a-12c. A plurality of branch ducts 101 which extend downwardly from the duct 100 and to a pan 102 which is disposed below the small diameter sections 11b, 11c and 11d. Each pan 102 has open sides presented to the large diameter sections 12a, 12b and 12c. In addition, the internal surface of the pans 102 may have a center peaked portion to prevent the cascading impact objects 17 from collecting therein. The heavier impact objects and the lighter bark, leaves and other debris will tend to fall into the lower ends of the large diameter sections 12a-12c. The action of the suction fan will create an outdraft through the gap between the lower ends of sections 12a-12c as indicated by arrows 104 and which is sufficiently strong to carry the lighter material into the air system 32 for discharge by fan 30.
In operation of the apparatus, the cylindrical sections 11a, 11b, 11c and 11d and the end sections 18 and 19 are rotated in a first direction and the large diameter sections 12a, 12b and 12c in an opposite direction by individual hydraulic motors, such as motor 52 shown in FIG. 6, and which are operated from a common pump (not shown). In addition, the hydraulic motor 94 (FIG. 7) is actuated to commence moving the belt 90 and rotating the recycle wheel 95 in a clockwise direction as viewed in FIG. 8. In addition, the suction fan 30 is actuated to begin drawing air from within the rotating sections 11a-11d and 12a-12c through the sides of the large diameter sections 12a, 12b and 12c around the baffles 103, through the pans 102 into the branch ducts 101, the main duct 100 and outwardly through the suction fan 30. One or more logs 16 or a plurality of smaller wood sections are fed into the apparatus through the infeed assembly 18. A plurality of impact objects 17 will have previously been disposed within the large diameter sections 12a, 12b and 12c and particularly section 12a. As a result of the rotation of the inlet section 18 and its forward tilt, as discussed hereinabove, the logs 16 and/or smaller wood sections will begin migrating toward the first small diameter section 11a which will initially engage the logs and continue their movement downstream of the apparatus. When the lead end of the log is engaged by the section 11a, the lugs 38 formed on the interior surface of said section will begin rotating the log as it progresses downstream. Meanwhile, the impact objects 17 will be raised upwardly within the pockets 43 formed in the large diameter sections 12a and be carried thereby upwardly as these sections rotate. It will be appreciated that the height to which the objects 17 are raised within the cylindrical sections 12a, 12b or 12c will be dictated by the speed of rotation. It will be appreciated that the speed of sections 12a-12c should be sufficiently great to carry the objects toward the upper end of the apparatus but less than the critical speed which would tend to hold the impact objects within the pockets 43. Approximately 70% of this critical centrifugal speed is satisfactory. The impact objects 17 should generally have a density several times greater than that of the logs being debarked.
As the logs 16 progress downstream, the lead ends thereof will soon pass into the larger diameter section 12a but will be supported in an elevated position with respect thereto by the smaller diameter section 11a and the infeed assembly 18. The cascading impact objects 17 will begin delivering generally uniform and randomly distributed surface impacts and abrasions on the log 16 as the latter is rotated by the lugs 38 in the smaller diameter section 11a. If the unit energy of each impact lies above a critical level determined by the wood specie and condition, the gradual and uniform degrading of the bark structure occurs whereby the bond between the bark and the wood is ultimately weakened and that the bark is soon stripped away.
As a result of the slight tilt of the cylindrical sections 11a-11d and 12a-12c, the log 16 and the impact objects 17 will tend to migrate downstream toward the discharge assembly 19 while the debarking process continues as incremental portions of the log 16 move downstream through the rotating cylindrical sections. The continued random impacts of the objects 17 on the log 16 will eventually remove all of the bark. It will also be appreciated that because the small diameter sections 11a-11d and the large diameter sections 12a-12c are independently rotatable, the speed of migration of the log 17 downstream of the apparatus, as determined by the speed of the small diameter sections 11a-11d, is independent of that speed of rotation of the large diameter sections 12a, 12b and 12c which is necessary in order to sufficiently elevate the impact objects 17 without exceeding the critical centrifugal speed. As the bark is thus removed, the air blast created by the suction fan 30 tends to discharge the dislodged bark from the system where it may be conveniently collected and disposed of. In addition, as the impact objects 17 reach the cylindrical discharge chamber section, they will fall through the bars 25 for being recycled by the assembly 32.
It will be appreciated also that as the logs 16 or other wood sections enter the infeed assembly 18, loose dirt, gravels and other foreign particles will tend to be dislodged and fall through the screen or perforation which form the sides of the inlet cylindrical section 20. Other loose debris and leaves are collected by the air discharge system 28 as indicated above.
It will be appreciated from the foregoing that the system according to the invention provides a continuous debarking process and apparatus wherein the logs 16 or other wood sections are delivered to one end of the system and debarked logs delivered from the other end while the impact objects 17 are circulated. While four small diameter sections 11a-11d and three large diameter sections 12a-12c are illustrated, it will be appreciated that the number of each and their length can vary with the size of the logs to be debarked, the number of impacts necessary to debark a particular log, the desired system capacity and the speed that the wood sections migrate through the system, the latter of which is also dependent, to some extent, upon the angle of tilt of the cylindrical sections and the speed of the small diameter sections 11a-11d.
While the invention has been discussed generally with respect to the debarking of logs, it will be appreciated that smaller size wood sections or tree limbs, such as those shown in FIG. 7, may be debarked as well. These smaller wood sections may vary in length to a substantial degree, it being appreciated, however, that smaller tree limb sections having a length shorter than the distance between the smaller diameter sections 11a-11d, will tend to fall within the large diameter sections and tumble along with the impact objects 17. This action, however, will also cause debarking as a result of random impacts by the objects 17. As a result, the same apparatus can be employed for debarking both logs and tree limb or top segments. It can also be seen that as the impact objects 17 migrate through the system they will pass through the small diameter sections 11b, 11c and 11d although the ribs 38 on the sides of said section will generally be insufficient to raise them more than a small vertical distance after which they will tend to tumble back into one of the adjacent large diameter sections 12a, 12b, or 12c.
The continuous process illustrated permits the debarking of wood sections without sorting or recycling and permits total debarking while maintaining the entrance to exit distance relatively short. For many species of wood, there is a definite difference between the bark breakdown energy and the wood breakdown energy. The action within the debarking apparatus consists of selective abrading, crushing and shearing of the bark in preference to the wood fiber. This preferential action is enhanced by the fact that most bark is normally more brittle than the wood it is associated with and hence more susceptible to impact crushing. If the elevation to which the impact objects are raised is such that the energy level at the point of impact with the various logs 16 or other wood sections is somewhere between the two critical energy levels, suitable rapid destruction of the bark will occur with relatively little damage to the wood. Also, because the process exposes the surface of the wood pieces or logs to uniformly distributed energy delivery, the roundness and symmetry is not important and shape becomes relatively insignificant. Irregularly shaped wood pieces and logs with small extending branch limbs may be efficiently debarked with very little loss of wood fiber. Effective debarking can therefore be achieved regardless of size and shape of logs or tree sections.
The size, shape, hardness and density of the impact objects may vary widely. Examples of insatisfactory impacting objects are mild steel slugs having generally cubicle cylindrical or disk-like shapes about one to two cubic inches in volume. Also, typical ceramic or metallic material used in ball mills or even stone or crushed rock may be employed.
The debarked wood produced in the apparatus according to the invention will generally be sufficiently clean for chipping into wood pulps or flaking for particle board use. The structure according to the invention provides an efficient and economical apparatus for debarking logs and which may also be employed for debarking tree limbs and tree top sections which are now normally discarded. This not only provides an economical use for such tree sections but also allows the use of trees which were heretofore not suitable because of size or shape.
Those skilled in the art will appreciate that the apparatus and method according to the invention may also be applied for the removal of any undesired matter from logs or wood sections. For example, plaster could be removed from wood salvage from demolished buildings, rock or ice removed from log sections and bark from sawmill slabs.
While only a single embodiment of the invention has been disclosed and described, it is not intended to be limited thereby but only the scope of the appended claims.
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Logs or tree limb sections to be debarked and a plurality of smaller, higher density impact objects are disposed in a series of interfaced, open-ended cylindrical sections, alternate ones of which have different diameters and are rotated in opposite directions about generally horizontal axes. The cylindrical sections are generally tangent about a point above their rotational axes and their upper ends are inclined slightly to promote migration of the impact objects and wood sections in series through the chambers and for discharging the same from the final chamber. At least the larger diameter sections include conveyers for carrying the impact objects upwardly and for releasing the same for impacting engagement against the wood sections to be debarked and an external conveyer recycles the impact objects from the final to the initial cylindrical section. An air delivery system discharges dislodged bark and other foreign material from the cylindrical sections.
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CROSS-REFERENCE
[0001] This is a continuation-in-part of U.S. patent application Ser. No. 09/391,076, filed Sep. 4, 1999.
BACKGROUND OF THE INVENTION
[0002] (a) Technical Field of the Invention
[0003] This invention is related to an improved tooth cleaning assembly.
[0004] (b) Description of the Prior Art
[0005] Generally, a person keeps a toothbrush, toothpaste, and a mug separately on a vanity cabinet in the bathroom When the person wants to brush his teeth, it is necessary to hold the toothpaste with one hand, open the cap of the toothpaste with another hand, set down the cap, pick up the toothbrush, squeeze the toothpaste on to the toothbrush, and then put the toothpaste back in the vanity cabinet, creating an inconvenient operation. Hence, various kinds of toothpaste squeezers have been developed to streamline this process, but it is still necessary to align the toothpaste with the toothbrush and squeeze the toothpaste onto the toothbrush, thus making the squeezers unsatisfactory for practical use.
[0006] Therefore, it is an object of the present invention to provide a tooth cleaning assembly which can obviate and mitigate the above-mentioned drawbacks.
SUMMARY OF THE INVENTION
[0007] This invention is related to a tooth cleaning assembly.
[0008] It is the primary object of the present invention to provide a tooth cleaning assembly which combines all commonly used tooth cleaning articles into one unit thereby making them convenient to use and arranging them in a tidy manner.
[0009] It is another object of the present invention to provide a tooth cleaning assembly which enables one to choose the desired toothbrush and toothpaste easily by the rotation of the annular member and the toothpaste squeezing assembly.
[0010] It is still another object of the present invention to provide a tooth cleaning assembly which will automatically apply toothpaste to a desired toothbrush.
[0011] It is still another object of the present invention to provide a tooth cleaning assembly which is compact.
[0012] It is a further object of the present invention to provide a tooth cleaning assembly in which the toothbrush and toothpaste can be foldably connected, thus making them easy to carry and suitable for practical use.
[0013] The foregoing objects and summary provide only a brief introduction to the present invention. To fully appreciate these and other objects of the present invention as well as the invention itself, all of which will become apparent to those skilled in the art, the following detailed description of the invention and the claims should be read in conjunction with the accompanying drawings. Throughout the specification and drawings identical reference numerals refer to identical or similar parts.
[0014] Many other advantages and features of the present invention will become manifest to those versed in the art upon making reference to the detailed description and the accompanying sheets of drawings in which a preferred structural embodiment incorporating the principles of the present invention is shown by way of illustrative example.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is a partially exploded view of the present invention;
[0016] [0016]FIG. 2 is a perspective view of the present invention;
[0017] [0017]FIG. 3 is an exploded view of the toothpaste squeezing device;
[0018] [0018]FIG. 4 is a sectional view of the toothpaste squeezing device;
[0019] [0019]FIG. 5A is a sectional view illustrating the engagement between the annular member and the cover;
[0020] [0020]FIG. 5B is a sectional view illustrating the engagement between the base and the detachable knob;
[0021] FIGS. 6 A- 6 B show a second preferred embodiment of the annular member and the cover;
[0022] FIGS. 6 C- 6 D shows a second preferred embodiment of the base of the toothpaste squeezing assembly;
[0023] FIGS. 7 A- 7 L illustrate another six preferred embodiments of the annular member of the toothpaste squeezing assembly;
[0024] [0024]FIGS. 8A and 8B illustrate front and side views of a second preferred embodiment of the toothbrush and toothpaste squeezing assembly unfolded;
[0025] [0025]FIGS. 9A and 9B illustrate a front and side views of the second preferred embodiment of the toothbrush and toothpaste squeezing assembly folded;
[0026] [0026]FIG. 10 illustrates another preferred embodiment of the toothbrush and toothpaste squeezing assembly;
[0027] [0027]FIG. 11 is a perspective view of the spring mug;
[0028] [0028]FIG. 12 is an exploded view of the spring mug; and
[0029] [0029]FIG. 13 is a view of the rack.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings. Specific language will be used to describe same. It will, nevertheless, be understood that no limitation of the scope of the invention is thereby intended, alterations and further modifications in the illustrated device, and further applications of the principles of the invention as illustrated herein being contemplated as would normally occur to one skilled in the art to which the invention relates.
[0031] With reference to the drawings and in particular to FIG. 1 thereof, the tooth cleaning assembly according to the present invention generally comprises toothpaste squeezing assemblies 10 and 10 M, tooth brushes 40 and 40 M, spring mugs 60 and 60 M, and a rack 70 . Referring to FIGS. 2,3 and 4 , the toothpaste squeezing assembly 10 includes caps 12 , tubular necks 14 A, 14 B, 14 C and 14 D, toothpaste cylinders 19 , an annular member 32 with slots 33 , a cover 30 , a base 34 and a movable cap 37 . The caps 12 , tubular necks 14 A, 14 B, 14 C and 14 D and toothpaste cylinders 19 are joined together to form the toothpaste squeezer 10 . The movable cap 37 is engaged with the base 34 . The toothpaste cylinder 19 is fitted in the hole 36 of the base 34 and held in place by the hooks 35 . The upper end of the toothpaste cylinder 19 is engaged with the cover 30 which is in turn held in place by the annular member 32 . The outlet 21 at the top of the toothpaste cylinder 19 is connected with the lower end of the tubular neck 14 C.
[0032] As shown in FIGS. 3 and 4, the toothpaste squeezer 10 includes a cap 12 , having a bottom connected with the outer upper tubular neck 14 B. The cap 12 has two through holes 16 and 16 A. The hole 16 is connected to outer tubular neck 14 B by pins, and through hole 16 A is also connected to inner tubular neck 14 A by pins. The inner upper tubular neck 14 A is slidably fitted within the outer upper tubular neck 14 B and provided with a projection 20 at the lower end. A spring 18 is fitted between the inner and outer upper tubular necks 14 A and 14 B. The lower end of the outer upper tubular neck 14 B is slidably fitted in the outer lower tubular neck 14 D which is formed integrally with the cover 30 . The inner lower tubular neck 14 C is slidably fitted within the outer lower tubular neck 14 D and engaged with the outlet 21 of the toothpaste cylinder 19 through threads 25 or conical circular portions (not shown). The annular member 32 is mounted on the outer edge of the cover 30 . A piston 20 A is fitted inside the lower end of the toothpaste cylinder 19 thereby forming a chamber for receiving toothpaste 22 . The piston 20 A is provided with a non-return member 23 and a bottom cover 24 . The toothpaste squeezer 10 is fitted in the hole 36 of the base 34 , with the hooks 35 supporting the toothpaste cylinder 19 . The movable cap 37 has an engaging member 38 engaged with the engaging member 35 A of the base 34 .
[0033] When in use, it is only necessary to press the front portion of the cap 12 so that the lugs 15 A of the inner upper tubular neck 14 A act as a main axle in the axle holes 15 B of the outer upper tubular neck 14 B. The inner upper tubular neck 14 A is lowered to open the cap 12 to expose the outlet 13 by pressing on the cap 12 . As pressure is maintained on the cap 12 , the piston 20 A is blocked by the non-return member 23 , thereby squeezing toothpaste 22 out of the outlet 13 and applying it to the head of the tooth brush. The toothbrush 40 and/or 40 M is then removed for use.
[0034] Meanwhile, the spring 18 forces the tubular necks 14 A and 14 B and the cap 12 to return to their original positions. Then, the cap 12 is moved by the upward force of the axle 15 A to close the outlet 13 . Since the tubular necks are smaller than the toothpaste cylinder 19 , the toothpaste will adhere to the tubular necks more than to the toothpaste cylinder 19 so that the piston 20 and the non-return member 23 will move upwardly to be in position for future use.
[0035] The lower end of the outer upper tubular neck 14 B, the inner lower end of the outer lower tubular neck 14 D, the inner upper end of the cover 30 , and the upper end of the toothpaste cylinder 19 are formed with conical circular portions 26 A and 26 B. The upper end of the outlet 21 and the lower end of the outer upper tubular neck 14 B are formed with engaging threads 27 so that the toothpaste cylinder 19 can be replaced.
[0036] In addition, the cap 12 may be provided with a sound card, an air whistle (not shown) or a music integrated circuit so that when the cap 12 is opened, sounds will be generated. Furthermore, the tubular necks 14 C and 14 D, the cover 30 , the toothpaste cylinder 19 and the base 34 may be partially or entirely formed integrally. The hook 35 must be made as an independent component so as to enable the user to replace the toothpaste cylinder 19 from the bottom.
[0037] [0037]FIG. 5A is a sectional view showing the engagement of the cover 30 and the annular member 32 . FIG. 5B is a sectional view illustrating the engagement of the base 34 and the detachable knob 37 . FIGS. 6 A-D illustrate a second preferred embodiment of the present invention, wherein the annular member 32 A, the cover 30 A and the base 34 A are formed with two holes, and the annular member 32 A may be wavy in shape. In addition, the toothpaste squeezer may be directly engaged with the detachable knob 37 at the bottom and with a single-hole annular member 32 B at the top. Further, as shown in FIGS. 7 A-L, the ears 33 , 33 A and 33 B of the annular members 32 , 32 A and 32 B may be of different types so as to be adapted for use with different types of toothbrushes 40 , 40 M, and hooks 42 . In other words, the present invention may be provided with one or more toothpaste squeezers to form a desired toothpaste squeezing assembly 10 . The small lug 33 C is a hook that can be used to hang a long-handled dental mirror (not shown).
[0038] [0038]FIGS. 8A and 8B illustrate the engagement of a toothbrush 40 M with a small toothpaste squeezing assembly 10 M. FIGS. 9A and 9B illustrate how the toothbrush 40 M is folded in a small toothpaste squeezing assembly 10 M. As shown, the small toothpaste squeezing assembly 10 M includes a seat 51 and a spring 52 . A short-handled toothbrush 40 M is pivotally connected to the seat 51 by an axle 43 . The toothbrush 40 M is normally disposed in a straight position so that its hook 42 hangs on the annular member 57 . When a user wants to remove the toothbrush 40 M from the assembly, the user rotates the toothpaste squeezing assembly 10 M through an angle of 180 degrees toward the bristles of the toothbrush 40 M so that the hook 42 M slides through the hole 44 (see FIG. 10).
[0039] Referring to FIG. 10, when in use, the cap 12 A is depressed to squeeze the toothpaste 22 out of the tubular neck 14 A of the toothpaste cylinder 19 A. The paste 22 comes out of the outlet 13 A, and the protuberance 58 of the annular member 57 is pressed to disengage the hook 42 M from the annular member 57 , thus causing the toothbrush 40 M to move to a straight position for use. The toothbrush 40 M may be folded after use, thereby making it convenient to carry. The toothbrush 40 M, the axle 43 , and the seat 51 can be connected together by a connecting plate, and partially or wholly made by injection molding. The tubular neck 14 C may be connected to the toothpaste cylinder 19 A to make it disposable after use.
[0040] Referring to FIGS. 1, 6A, 6 B, 8 A, 8 B, 9 A and 9 B, each of the toothbrushes 40 and 40 M is provided with a hook for hanging on the lug 33 C of the annular member 32 A and an axle 43 for engaging with the seat 51 of the toothpaste squeezing assembly. Each of the hooks 42 and 42 M and the axle 43 are designed to make the bristles of the toothbrush align with the outlet 13 . However, for electric toothbrushes, the hook may be provided on a detachable power handle. The toothbrush may be made of resilient foam plastic.
[0041] [0041]FIGS. 11 and 12 are a perspective view and an exploded view of the spring mug 60 , respectively. As shown, the spring mug 60 is made of a body 61 , a bottom member 64 , a ring member 63 , a spring 67 and a handle 62 . The body 61 has an annular groove 66 formed with three cavities 661 . One of the cavities 661 receives the spring 67 . The bottom member 64 has a flange 65 formed with three projections 651 . The bottom member 64 engages the body 61 with the projections 651 slidably fitted into the cavities 661 . The ring member 63 is sleeved over the bottom member 64 to be fixedly mounted with the body 61 , thereby retaining the bottom member 64 in the body 61 . Normally, the spring 67 forces the bottom member 64 to position with the recessed portion 69 engaging the ring member 63 so that the spring mug 60 can be fitted into the lower portion of the rack 70 . When the spring mug 60 is removed from the rack 70 , the protuberances 73 at two sides of the rack 70 will adjust the position of the bottom member 64 , thereby causing the spring 67 to force the bottom member 64 outward, thereby increasing the capacity of the spring mug 60 . The annular groove 66 with three cavities 661 may be replaced with a larger circular groove adapted to receive a single spring.
[0042] Referring to FIG. 13, the upper portion of the rack 70 is formed with a protrusion 71 adapted to engage a cavity 39 at the lower end of the toothpaste squeezing assembly 10 . The interior of the rack 70 is divided by two partitions into three chambers for receiving spring mugs 60 . The rack 70 has two holes 74 for hanging the rack on the wall.
[0043] The above-mentioned component parts form the tooth cleaning assembly according to the present invention. The rack 70 receives the toothpaste squeezing assembly 10 , on which are hung toothbrushes 40 and 40 M. Spring mugs 60 or 60 M are fitted within the rack 70 .
[0044] While certain novel features of this invention have been shown and described and are pointed out in the annexed claims, it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in itsoperation can be made by those skilled in the art without departing in any way from the spirit of the present invention. Accordingly, the above disclosure should be construed as limited only by the restrictions of the appended claims.
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A tooth cleaning assembly including a rack, and at least one detachable toothpaste squeezing assembly mounted on the rack. The assembly further includes a base, a toothpaste cylinder having a lower end fitted in the base, an annular member arranged at an upper end of the toothpaste cylinder, a cover fitted on a top of the toothpaste cylinder and mounted on the annular member, a tubular neck telescopically fitted in the toothpaste cylinder, a cap pivotally connected with an upper end of the tubular neck, and a movable knob extending through the rack to be detachably engaged with a bottom of the base. At least one toothbrush is detachably mounted on the annular member, and at least one spring mug is fitted within the rack, so that all commonly used tooth brushing articles are combined into one unit thereby making them convenient to use and arranging them in a tidy manner.
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This Application claims benefit to Provisional Application No. 60/122,935 filed Mar. 5, 1999.
FIELD OF THE INVENTION
The present invention relates generally t o methods and apparatus for maintaining a sanitary condition in an ice maker, and in particular to such methods and apparatus using the generation of chlorine as a sanitizing a gent.
BACKGROUND OF THE INVENTION
The need to keep ice making and dispensing equipment clean over time is well known in the art. It is understood that such equipment can become contaminated with microorganisms, such as, bacteria, yeast, fungi, and mold. Thus, for example, the ice forming evaporator, fluid lines and ice storage area found in such equipment must be periodically cleaned.
Manual cleaning with detergents and sterilizing chemicals can be effective, however, cleaning schedules are not, as a practical matter, always adhered to. In addition, the job may not be done satisfactorily in terms of a thorough cleaning and rinsing of the food contact and drain elements or tubes. Thus, systems have been developed including electronic controls that, in the case of an ice maker, automatically enter the machine into a sanitizing cycle wherein cleaning agents are pumped there through and subsequently rinsed off. Of course, the automatic systems can fail as well, where, for example, the cleaning agent reservoir runs out of cleaner, or the apparatus simply breaks down or fails to operate properly. Accordingly, a more reliable low cost method of maintaining an ice maker in a sufficiently sanitary condition that is less susceptible to human error or mechanical break down would be desirable.
SUMMARY OF THE INVENTION
The present invention is an apparatus and method for providing effective chlorination of water used in ice making equipment for the production of ice cubes for sanitizing and retarding the growth of micro-organisms therein.
As is known, an ice maker typically includes refrigeration components including a compressor, a condenser for cooling an evaporator. The evaporator is integral with an ice forming grid having the individual pockets in which the ice cubes are formed. As is also known in the art, the ice maker ,as above described, includes a water pump that operates to pump water from a source thereof to a water distribution tube located along and above the ice forming grid. The water then exits the distribution tube and cascades over the surface of the vertically oriented grid/evaporator. As the ice forming grid is cooled by contact with the evaporator during operation of the refrigeration system, some of the water flowing there over will freeze thereon. The remainder of the water will flow into a receiving tank to be recycled by the pump to flow repeatedly over the evaporator until ice of a sufficient thickness is formed thereon. The ice is then harvested, typically by hot gas defrosting of the evaporator, causing the ice to melt slightly and slip off the grid structure and drop into an ice retaining bin there below.
An electronic chlorine generating device, as manufactured by Sanyo Electric Co. Ltd. Of Japan is used to produce bacterially active chlorine gas Cl 2 from chloride ions. Such generators are described in Japanese patents 5269469 A, 2190994 A, 2031886 A and 61283391 A, which patents are incorporated herein by reference thereto. As is understood, such generators include a pair of electrodes for creating an electrolytic reaction wherein a relatively biologically inactive chloride ion, present in municipal tap water, is converted to the more biologically active growth retarding or inhibiting chlorine gas. In the present invention, the pair of electrodes are positioned in the water receiving tank of the ice maker. In operation, a potential is periodically applied between the electrodes for predetermined periods of time to produce the active chlorine to a desired level. It was found that by enriching the Cl 2 content of the water, growth of microorganisms on the evaporator, the receiving tank, the distribution tube and the tubing associated there with was greatly reduced or eliminated.
DESCRIPTION OF THE DRAWINGS
A further understanding of the structure, function, operation, and objects and advantages of the present invention can be had by referring to the following detailed description that refers to the following figures, wherein:
FIG. 1 shows a schematic diagram of the present invention.
FIG. 3 shows a front plan schematic view of an ice maker.
FIG. 3 shows an enlarged perspective view of a receiving tank, ice forming grid/evaporator and water distribution tube.
FIG. 4 shows top plan view along lines 4 — 4 of FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A schematic view of the modified ice maker sanitizing system of the present invention is seen in FIG. 1 and generally referred to by the numeral 10 . As can be understood by also referring to FIG. 2, system 10 is used in the context of an ice maker 12 having an ice forming evaporator 14 , a distribution tube 16 . Refrigeration system includes a compressor 18 a , a condenser and fan motor 18 b and 18 c respectively. System 10 also includes a water circulating pump 20 and a water receiving tank 22 . Tank 22 includes a float valve 24 connected to a line 25 connected to a source of municipal water. Valve 24 regulates the supply of water into tank 22 as is required to replenish that which is formed into ice and that which is periodically dumped there from. A fluid line 26 connects pump 20 to tank 22 and to distribution tube 16 . A solenoid S provides for the above mentioned dumping of water in tank 22 to a drain. As is well understood, a refrigeration control 27 controls the operation of ice maker 12 to determine, for example, when ice is of sufficient thickness on evaporator 14 so as to initiate harvest thereof.
As seen by referring to FIG.'s 3 and 4 , a chlorine generator, as manufactured by Sanyo Electric co. Ltd. Of Japan, includes a chlorinator control box 28 connected by wires 28 a to a pair of flat plate electrodes 30 . Electrodes are kept spaced apart by an insulating plug 30 a . Ice maker 12 includes a bottom ice retaining bin 31 and a top housing 32 . Housing 32 is divided into a separate refrigeration component section 32 a and a separate ice making section 32 b . Control box 28 is located in refrigeration component section 32 a wherein wires 28 a provide connection to electrodes 30 positioned to extend horizontally in tank 22 in a sump area 34 thereof. Control 28 is connected to a suitable source of electrical power and is also electrically connected to refrigeration control 27 .
In operation, in the ice making mode, water is circulated by pump 20 to exit distribution tube 16 and cascade over evaporator 14 . The refrigeration system is simultaneously operated to cool evaporator 14 so that ice forms thereon. Water that does not freeze on evaporator 14 falls into tank 22 to be recirculated therefrom by pump 20 over evaporator 14 until ice of sufficient thickness has formed thereon. Control 27 senses when sufficient ice has formed and causes harvesting thereof by a hot gas defrost process, well understood in the art. After harvesting and prior to the next ice making cycle, a portion of the water in tank 22 is drained therefrom to remove any impurities therein. Valve 24 then opens to maintain the water in tank 22 to a predetermined level L above electrodes 30 . After the dumping process, but before the start of a further ice making cycle, control 28 then provides for an electrical potential between electrodes 30 for the formation of chlorine. Specifically, the chemical reactions can be characterized as:
Anode reaction:
2Cl − →Cl 2 +2e
4OH−→O 2 +2H 2 O+4e
Cathode reaction:
2H + +2e→H 2
As is understood, the C 12 gas dissolves in water by the reaction:
Cl 2 +H 2 O→HClO+HCl
HClO→H + +CLO −
Control 28 operates on a pre-set time basis. In particular, it is set to provide an electrical potential for a predetermined period of time that will produce chlorine at a nominal level of approximately 0.5 parts per million. This level was determined to have a sufficient bacteriostatic effect, yet not be so high that any bad taste was imparted to the ice or that it would be in any way unsafe for consumption. In a particular embodiment of the present invention, the tank 22 has a volume of approximately 2 quarts wherein electrodes 30 are energized for a period of 40 seconds between each ice making cycle. Each ice making cycle lasts approximately 15 minutes. Control 28 also operates during non-ice making times, such as when bin 31 is full and no further ice making is required. In the specific embodiment referred to above, control 28 energizes the electrodes 30 every 4 hours during periods of non ice making. Such chlorine production during non ice making intervals is important to prevent microorganism growth in tank 22 , as the water is stagnant therein and tends to warm up. The 0.5 part per million level, though relatively low, was found to be effective in the present invention due to the cold temperature of the circulated ice making water. The temperature of the circulated water was found to keep the chlorine in solution rather than being lost to evaporation. Thus, the chlorine is kept in the water to provide for a bacteriostatic effect rather than being lost to the atmosphere. Hence, a lower nominal level can be effective as opposed to a situation where the water would be of a warmer temperature.
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The present invention is an apparatus and method for providing effective chlorination of water used in ice making equipment for the production of ice cubes for sanitizing and retarding the growth of micro-organisms therein. A chlorine generator is used to produce chlorine gas from chloride ions present in the water.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for preparing polyester fibers which are superior in water absorbency when compared to those of cotton and wool.
2. Description of the Prior Art
Polyester fibers are usually prepared mainly from terephthalic acid or aromatic dicarboxylic acid, such as 2,6-naphthalenedicarboxylic acid, or their ester derivatives, and ethylene glycol through polycondensation.
Polyester fibers are superior in mechanical properties and thermal resistance, but poor in water absorbency, when compared to natural fibers, such as regenerated cellulose, because polyester fibers have a structure of high crystallinity and few water-affinitive groups, e.g., hydrophilic groups in their molecules. The term “water absorbency” as used herein means the extent to which fiber mass, such as filaments, strands, textile fabrics, knitted goods, non-woven fabrics and the like, absorbs water. Where water absorbency is needed, the use of polyester fibers may cause a problem.
For this reason, active research has been directed to the development of polyester fibers which are of excellent water absorbency while retaining their physical properties.
For example, U.S. Pat. No. 3,329,557 and U.K. Pat. No. 956,833 disclose that polyester can be blended with hydrophilic polyalkylene glycol before spinning. The polyester fibers thus obtained, however, show fairly deteriorated physical properties in addition to not reaching a satisfactory level of water absorbency.
Korean Pat. Publication No. 93-6779 discloses a polyester with an organic compound having polyalkylene or polyamine as a main chain. Disclosed in Korean Pat. Publication No. 86-397 is a polyester mixed with the eluting agent ROSO 3 M (wherein R is an alkyl group containing 1-30 carbon atoms or an alkylaryl group containing 7-40 carbon atoms and M is an alkaline metal or an alkali earth metal) and spun and the fibers are made porous by elution treatment with an aqueous alkaline solution. These polyester fibers are significantly improved in water absorbency, but suffer from a significant disadvantage of being expensive. The additives are highly priced and additional processes increased the high production cost.
It is also known that polyester fibers are provided with hydrophilicity by addition with colloidal silica particles. This causes likewise an increase in production cost.
It is also known that polyester fibers are provided with hydrophilicity by addition with colloidal silica particles. This causes likewise an increase in production cost.
SUMMARY OF THE INVENTION
Therefore, it is an object of the present invention to overcome the above problems encountered in the prior art and to provide a method for preparing polyester fibers which show excellent water absorbency as well as physical properties.
It is another object of the present invention to provide a method for preparing polyester fibers, which does not significantly increase the production cost.
In one embodiment of the present invention, there is a method for preparing polyester fibers of excellent water absorbency, in which inorganic particles are added at an amount of 0.01-50 weight %, based on the total weight of the fibers, at a suitable addition time from polyester polymerization to a stage before spinning. In one aspect, the addition time is selected from a polyester polymerization stage, a stage in which polyester is flowed under pressure to a spinneret, and a stage in which polyester is melt-extruded to chips. In another aspect of the embodiment, the inorganic particles are selected from the group consisting of calcium oxide particles, magnesium oxide particles, manganese oxide particles and mixtures thereof and range in size from 0.01 to 50 μm.
DETAILED DESCRIPTION OF THE INVENTION
Polyester is usually prepared from polycarboxylic acid and polyhydric alcohol. For the polyester fibers of the present invention, aromatic dicarboxylic acid or its ester derivatives are employed. Examples of the aromatic dicarboxylic acid useful in the present invention include isophthalic acid, terephthalic acid, 2,6-naphthalenedicarboxylic acid, phthalic acid, adipic acid, sebacic acid, and mixtures thereof. As the polyhydric alcohol, ethylene glycol is mainly used, together with a small amount of other alcohols, such as propylene glycol, butanediol, 1,4-cyclohexanediol and neopentylglycol.
If necessary, additives such as thermal stabilizers, anti-blocking agents, antioxidants, antistatic agents, UV absorbents, etc, may be used in preparing polyester fibers.
In accordance with the present invention, inorganic particles are used in preparing polyester fibers, in order to endow the polyester fibers with high hydrophilicity. The inorganic particles are selected from the group consisting of calcium oxide particles, magnesium oxide particles, manganese oxide particles, and mixtures thereof.
As for the addition time of the inorganic particles during the preparation of polyester fibers, it may be selected from a polyester polymerization stage, a stage in which polyester is flowed under pressure to a spinneret, and a stage in which polyester is melt-extruded to chips.
In the polyester polymerization stage, the inorganic particles are preferably added at the time just after completion of the esterification step, or at the time of the polycondensation step. In this regard, the inorganic particles to be added must not contain moisture lest the reaction is inhibited.
After being polymerized through polycondensation, polyester is transferred under pressure to a spinneret in order to spin polyester fibers. In the course of this transfer, calcium oxide particles, magnesium oxide particles, manganese oxide particles or mixtures thereof may be added. In this connection, some of the polymer is drawn from the transfer pipe, added with the inorganic particles, and returned to the remaining polymer in the pipe.
When the polyester polymerized is transferred to an extruder to produce polyester chips, the inorganic particles are fed directly. The inorganic particle-containing polyester chips can be used in the present invention, alone or in combination with other polyester chips.
Typically, calcium oxide particles can be obtained from calcium carbonate ores. First, calcium carbonate ores are pulverized to small pieces and baked at about 1,000° C. in a furnace to separate calcium oxide and carbon oxide. Calcium carbonate particles are advantageous in that they are easily obtained and low-priced owing to simple manufacturing processes. When encountered with water, calcium oxide is readily converted into calcium hydroxide (Ca(OH) 2 ). Accordingly, this high hydrophilicity of calcium oxide enables the polyester fibers to have excellent water absorbency. This mechanism of improving water absorbency is true of magnesium oxide and manganese oxide.
Preferably, the inorganic particles range, in size, from 0.01 to 50 μm. For example, when inorganic particles with a size less than 0.01 μm are used, a great improvement is not brought about in the water absorbency. On the other hand, inorganic particles greater than 50 μm readily cause fiber cutting upon spinning processes or after-treatment processes. The inorganic particles are preferably used at an amount of about 0.1-50 weight %, based on the weight of the polyester. For example, the amount smaller than 0.1 weight % gives a trace contribution to the improvement in water absorbency while the amount greater than 50 weight % deleteriously affects the physical properties of the polyester.
As mentioned above, the inorganic particles must not contain water nor impurities, otherwise, deterioration is found in the spinnability and after-treatment process. Further, because the presence of inorganic particles in polyester is a direct factor to abrade the physical properties of the polyester, it is preferred that the inorganic particles be as pure as possible.
A better understanding of the present invention may be obtained in light of the following examples which are set forth, but are not to be construed to limit the present invention.
EXAMPLE I
100 weight parts of terephthalic acid and 45 weight parts of ethylene glycol were placed in reactor, which then were esterified for 4 hours by heating to 140-230° C. with stirring. After being adding 0.04 weight parts of antimontrioxide and 0.015 weight parts of phosphoric acid per weight part of ethylene glycol, the esterified mixture was subjected to polycondensation at 230-285° C. for 4 hours under vacuum to give polyester I.
The polyester I was solidified with liquid nitrogen and pulverized to a powder. Thereafter, 80 weight parts of the powder were homogeneously mixed for 30 min with 20 weight parts of calcium oxide particles ranging in size, from 0.01 to 50 μm with an average size of 0.4 μm, followed by allowing the homogeneous mixture to go through a twin-screw melt-extruder which was being operated at 240-290° C. under vacuum, to give polyester II.
90 weight parts of the polyester I and 10 weight parts of the polyester II were mixed, dried at 160° C. for 6 hours with hot air, melted through a melt extruder which was being operated at 290° C., and spun through a spinneret, to give 75/24 polyester fibers.
EXAMPLE II
75/24 polyester fibers were prepared in a similar manner to that of Example I, except that 95 weight parts of the polyester I and 5 weight part of the polyester II were used.
COMPARATIVE EXAMPLE I
100 weight parts of terephthalic acid and 45 weight parts of ethylene glycol were placed in a reactor, which then were esterified for 4 hours by heating to 140-230° C. with stirring. After adding 0.04 weight parts of antimontrioxide and 0.015 weight parts of phosphoric acid per weight part of ethylene glycol, the esterified mixture was subjected to polycondensation at 230-285° C. for 4 hours under vacuum to give polyester I.
The polyester I was solidified with liquid nitrogen and pulverized to powder. Thereafter, 80 weight parts of the powder were homogeneously mixed for 30 min with 20 weight parts of colloidal silica particles with an average size of 0.3 μm, followed by allowing the homogeneous mixture to go through a twin-screw melt-extruder which was being operated at 240-290° C. under vacuum, to give polyester III.
90 weight parts of the polyester I and 10 weight parts of the polyester III were mixed, dried at 160° C. for 6 hours with hot air, melted through a melt-extruder which was being operated at 290° C., and spun through a spinneret, to give 75/24 polyester fibers.
COMPARATIVE EXAMPLE II
75/24 polyester fibers were prepared in a similar manner to that of Comparative Example I, except that 95 weight parts of the polyester I and 5 weight parts of the polyester III were used.
The polyesters obtained in Examples and Comparative Examples were measured for physical properties and the results are given in Table 1, below.
TABLE 1
Examples
Physical Properties
I
II
C.I
C.II
Denier
75/24
75/24
75/24
75/24
Strength (g/denier)
4.78
4.78
4.79
4.79
Elongation (%)
38.64
38.32
38.90
38.91
Water-Absorbency (wt %)
8.2
4.3
1.4
1.2
As apparent from the data of Table 1, the method according to the present invention provides polyester fibers with superior water absorbency and similar physical properties as fibers of the conventional method. In addition, the present invention has an advantage over conventional methods in that the production cost is significantly lowered due to the low-priced inorganic particles.
The present invention has been described in an illustrative manner, and it is to be understood that the terminology used is intended to be in the nature of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. Therefore, it is to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
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A method for preparing polyester fibers whose water absorbency is comparable to that of natural fibers in which, at a suitable addition time from polyester polymerization to a stage prior to spinning; hydrophilic inorganic particles such as calcium oxide particles, magnesium oxide particles, and manganese oxide particles are added at an amount of 0.01-50 weight % based on the total weight of the fibers. This method enables polyester fibers to have superior water absorbency as well as excellent physical properties. As the inorganic particles are low-priced, this helps to keep down the total cost of producing the fibers.
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BACKGROUND OF THE INVENTION
There are vast deposits of oil shale throughout the world with one of the larger deposits being in the Piceance basin of Colorado, Wyoming and Utah. This oil shale has carbonaceous materials known as kerogen which decompose on heating to produce shale oil which approximates crude petroleum. The vast oil shale deposits represent a very large source of oil for the world energy economy.
A variety of techniques have been proposed for extracting the shale oil at economical prices. Many of these techniques mine the oil shale by underground or open pit mining and carry it to large retorts where it is heated and the oil extracted. These approaches involve moving massive amounts of material to the retorts and disposing of enormous quantities of spent shale from which the carbonaceous values have been extracted.
Another approach which has significant economic advantages and minimal impact on the environment employs in situ retorting where the shale oil is removed without mining all of the oil shale. Such retorts can be formed, for example, by excavating a portion of rock in a volume that ultimately will become an underground retort. The balance of the rock in the volume to become a retort is then explosively expanded to form a rubble pile of oil shale particles substantially completely filling the retort volume. The original excavated volume is thus distributed through the expanded oil shale particles as the void volume therebetween.
Oil is then extracted from the expanded rubble pile in the underground retort by igniting the top of the rubble pile and passing an oxygen bearing gas, such as air, downwardly through the retort. Once raised to a sufficient temperature the oil shale will support combustion, initially at the top of the retort by burning some of the oil in the shale. Thereafter, as the oil is extracted there is residual carbon left in the shale and, when at a sufficient temperature, this too will react to oxygen to burn and supply heat for retorting. This burning of residual carbon in the shale depletes oxygen from the air being passed down through the retort and the substantially inert gas then carries heat to a retorting zone below the combustion zone for decomposing the kerogen and extracting oil. Gasses from the bottom of the retort are collected and often contain sufficient hydrogen, carbon monoxide and/or hydrocarbons to be burnable in heat engines. Oil is also collected at the bottom of the retort and transported for conventional refining.
When the oil shale is expanded in the underground retort, the particles ordinarily fill the entire volume so that there is no significant void space above the rubble pile. Air for combustion can be brought to the rubble pile by means of holes bored through overlying intact rock. Appreciable difficulty may be encountered, however, in igniting the top of the rubble pile to support combustion. Ignition requires a substantial amount of heat delivered over a sufficient time to raise the oil shale above its ignition temperature. Considerable difficulty is encountered in providing burners for such ignition and assuring that ignition has been obtained.
BRIEF SUMMARY OF THE INVENTION
There is, therefore, provided in practice of this invention according to a presently preferred embodiment, a gas-air burner in a cylindrical housing having a refractory nozzle at one end so that a flame exiting therefrom inpinges on oil shale in the rubble pile. Air and gas are brought in through an outer feed tube coaxial with the housing and communicating with the inlet end of the nozzle and an inner feed tube terminating in an open end spaced apart from the exit nozzle. A mixing chamber provides thorough mixing of the gas and air at the end of the inner feed tube and the mixed gas then passes through an orifice and past igniters enroute to the nozzle. A radiation sensitive flame sensor is mounted for viewing along the axis of the burner through the inner feed tube to verify that combustion is occurring in the burner.
DRAWINGS
These and other features and advantages of the present invention will be appreciated as the same becomes better understood by reference to the following detailed description of a presently preferred embodiment when considered in connection with the accompanying drawings wherein:
FIG. 1 illustrates in longitudinal cross section a burner constructed according to principles of this invention in place adjacent an oil shale rubble pile in an in situ retort;
FIG. 2 illustrates in longitudinal cross section a burner constructed according to principles of this invention;
FIG. 3 is a transverse cross section of a portion of the burner at line 3--3;
FIG. 4 is a fragmentary detail of the air line of the burner; and
FIG. 5 is a composite of FIGS. 2 and 4.
DESCRIPTION
FIG. 1 illustrates in vertical cross section and partly schematically a burner arrangement for igniting a rubble pile in an in situ oil shale retort. Only the very uppermost portion of the retort volume 10 is indicated in FIG. 1. This retort volume is simply cross-hatched as earth. However it will be understood that the volume is filled with irregularly-shaped particles of expanded oil shale, ordinarily fragmented by detonation of explosives. Above the ceiling 11 of the retort volume there is an overburden of intact rock 12. The thickness of this overburden is arbitrary and may be a few tens of feet in some retorting arrangements and may be hundreds of feet in others.
A cylindrical hole 13 is bored through the overburden 12 to the top of the rubble pile. This hole may be formed either before or after blasting to form the rubble pile of expanded shale, but is usually made subsequent to blasting. Such a hole may be made by conventional drilling techniques and reamed out to the desired size. If some or all of the over burden is permeable the hole may be cased with steel pipe or the like, and it is to be understood that reference herein to a hole includes either a simple bore through intact rock or a cased bore hole.
A larger diameter plenum 14 is formed at the lower end of the hole 13 with its lower end in communication with the top of the rubble pile. This plenum may extend below the ceiling 11 into the rubble for some distance, however, a principal portion of the plenum will ordinarily be formed in intact rock to assure that the plenum remains open. If a hole of any substantial height is formed in the rubble pile the irregular pieces of rock may collapse into the hole and block it. It is therefore, generally undesirable to form any great length of the plenum 14 in the rubble pile itself.
Such a plenum may be formed prior to blasting to form the rubble pile, however, the uncertainty that it will remain intact is such that it is preferable to form the plenum after blasting. If it is formed prior to blasting it should be inspected to assure that an appropriate plenum remains after blasting. The plenum is typically formed by lowering a conventional expanding underreamer or chambering tool down the hole 13 and reaming out an enlarged diameter. An appreciably enlarged plenum can be formed in this manner. For example, with a 10 inch diameter bore hole 13, a plenum in the range of 17 to 27 inches can be made with conventional tools. The length of height of the plenum need by only sufficient to accommodate a burner lowered therein and assure that particles of rubble do not sufficiently block the lower end of the plenum to inhibit the passage of combustion air therethrough.
After a suitable plenum is assured, a burner 16 is lowered down the hole by cable 17 connected to a winch 18 above the overburden. If desired, the burner can be lowered to a point that it is substantially completely in the plenum so that there is no obstruction of the hole 13 which would inhibit the passage of air therethrough. This is not necessarily required and if of small enough diameter, the upper portions of the burner can be in the hole 13 without unduly constricting air flow. Further, the quantity of air needed during ignition of the rubble pile may be less than needed during retorting thereof. Air is forced down the hole 13 into the rubble pile from any conventional blower or other air supply 19, indicated schematically in FIG. 1.
A "utility" umbilical 21 is connected to the burner 16 and extends up the hole 13 for operation of the burner. Compressed air 22 and a combustible gas 23 are fed down hoses in the umbilical for combustion in the burner. Propane, butane, natural gas, flue gas from oil shale retorting, or other combustible materials can conveniently be used. It will also be apparent, of course, that oxygen enriched air or mixtures of air and retorting flue gas can be used for either air supply 19 or 22.
A flame sensor 24 is also connected to the burner as hereinafter described to assure that ignition of the combustible gasses has occured and that heating of the oil shale is proceeding. Thermocouples may also be provided in the burner and a thermocouple measuring circuit 26 is also connected through the umbilical 21.
FIG. 2 illustrates in longitudinal cross section a presently preferred embodiment of burner useful in practice of this invention. As illustrated in this embodiment the burner has a cylindrical housing 27 which in a typical embodiment may simply be standard 8 inch steel pipe, although it may be desirable to form at least the lower end thereof of heat resistant stainless steel or the like. A steel bulkhead 28 is welded into the housing about 16 inches above the lower end and a ring 29 is welded in place at the lower end. A conventional castable refractory material 31, capable of withstanding elevated temperatures such as 3000° F. is cast in the space between the bulkhead 28 and ring 29. A conical exit nozzle 32 is formed along the axis of the refractory material with its larger end opening at the lower end of the burner. Steel reinforcing rings 33 are preferably embedded in the castable refractory to provide strength and integrity. The steel rings are conveniently held in place during casting of the refractory by radiating spiders (not shown) tack welded to the surrounding portion of the housing 27.
An outer feed tube 36 extends along the axis of the housing and has an open end welded into the bulkhead 28 to form an inlet for the nozzle 32. The other end of the outer feed tube 36 is closed and an air conduit 37 is welded into one side of the outer feed tube so that air for combustion in the burner can be introduced.
Gas is introduced to the burner through an inner feed tube 38 concentric with the outer tube. This tube extends upwardly or rearwardly through the closed end of the outer feed tube 36 and combustion gas is introduced through a side conduit 39. The lower end of the inner feed tube 38 is open. A series of helically extending vanes 41 are provided on the exterior of the inner tube 38 and serve to keep the lower end centered in the surrounding outer tube. These vanes also cause the air passing through the annulus between the tubes to be swirled for proper mixing with the combustible gas.
A mixing chamber 42 down stream from the open end of the inner tube 38 provides primary mixing of the swirling inlet air and the combustible gas. This mixture then passes through a smaller diameter orifice 43 where the enhanced velocity further assures turbulent mixing and retards propagation of flame to prevent flashback in the burner.
A pair of conventional igniter plugs 44 (FIG. 3) and an anode pin 46 are provided down stream from the mixing orifice 43 and upstream from the inlet to the nozzle 32. Electrical discharge between the igniter plug and the anode assures ignition of the mixed gas in the burner. A pair of igniter plugs are provided for redundancy. The castable ceramic of the nozzle portion extends into the region surrounding the igniters to provide thermal protection of these elements. A cavity 55 (FIG. 3) is left in the ceramic around the uppermost portion of the igniter plugs so that the area is left free of refractory to avoid shorting out the spark plug wires. A pair of small holes 56 extend through the housing 27 adjacent the igniters and holes 57 are provided through the bulkhead 28 for fluid communication with the balance of the burner housing. This allows circulation of cooling air around the plugs as pointed out hereafter.
An ultraviolet light sensor 47 is mounted on the end of the inner feed tube 38 removed from the nozzle. The field of view of the sensor 47 is along the axis of the burner so that the region of the nozzle and rubble pile beyond the nozzle are monitored. The ultraviolet sensor is sensitive to wave lengths of radiation found in flame and is used to verify that ignition of the gas has occurred in the burner.
After ignition of the gas-air mixture in the burner, the ultraviolet light flame sensor monitors the burning to assure continued combustion and that there is no hazardous generation of quantities of unburned combustible mixture. Such ultraviolet sensors for detecting flames are commonly used and are conventionally available items.
These sensors require high voltages for operation and in field use it is quite inconvenient to bring the necessary high voltages down the utility umbilical 21. The transformer 48 (FIG. 1) for the ultraviolet light sensor is therefore mounted within the housing that is lowered down the hole. The flame sensor circuit 24 at the surface therefore transmits relatively low voltage power which is stepped up at the burner and the low voltage signal from the sensor is returned to the ground surface for monitoring by operating personnel. By transmitting the lower voltage power through the umbilical, fewer problems of radiation shielding which might interfere with thermocouple measurements are encountered. Transmission of lower voltage power for the igniters with a step up transformer 50 in the burner capsule is also preferred.
When the burner is used the igniters are actuated and air and gas are passed through the respective feed tubes 36 and 38. This mixture is ignited and a strong flame is directed out of the lower end of the burner to impinge on the top of the rubble pile in the oil shale retort. This burning is conducted until a substantial volume of oil shale has been heated above its ignition temperature so that the combustion in the rubble pile is self sustaining. This vast amount of heat would rapidly destroy the burner and elements within it if steps were not taken to keep it cool. Air from the supply 19 is therefore forced down the hole at a sufficient rate that the cool air flow around the burner 16 maintains it at a safe operating temperature.
Additional cooling of the burner is provided by bypassing a portion of the primary air from the air supply 22 (FIG. 1). FIG. 4 illustrates in fragmentary detail an upper portion of the cylindrical housing 27 where the primary air line 37 passes through the top bulkhead 52 of the burner. A conventional bulkhead fitting 53 connects the air line and it might be noted that an absolutely fluid tight seal is not required through the bulkhead. A pair of 1/4 inch diameter holes 54 are formed through the wall of the air conduit inside the housing. Thus, a portion of the primary air "leaks" through the holes into the interior of the housing. The amount of air flow can readily be determined by conventional orifice formulas. FIG. 5 is a composite of FIGS. 2 and 4 indicating the location of the holes 54 adjacent the top bulkhead 52 of the burner.
A second pair of bleed holes 56 (FIG. 3) are provided through the wall of the housing by the igniters 44 near the bottom for the release of air. The air that flows from the housing mixes with the secondary air flowing around the burner. Thus, air is admitted to the top of the housing through the holes 54 and is bled out through the holes 56 so that there is circulation of air through the housing and around the various instruments therein. In effect, the support plates (not shown) for the instruments serve as baffles to help direct air flow and provide cooling in critical regions. The exit holes 56 are adjacent the igniters 44 so that there is good cooling of these elements and their lifetime is substantially prolonged.
Four tubes 49, equally spaced around the periphery, are welded between the ring 29 and bulkhead 28 so as to be closed at the lower end of the burner and open into the housing. A thermocouple 51 is positioned in each of the wells formed by these tubes 49 embedded in the refractory 31. These thermocouples monitor the temperature near the lower end of the burner where the most severe heating is encountered. This permits the operator to reduce the air and gas supply to the burner to lower the rate of heat generation or, if desirable, to increase the quantity of air flowing down the hole and around the burner to provide additional cooling.
It will be noted that the secondary air passed down the hole around the burner provides the oxygen for combustion of the carbonaceous material in the oil shale heated by the burner. It also carries heat of the flame into the bed of oil shale particles for heating a substantial volume of the bed. As heating of the shale continues, a greater portion of the total heat adjacent the top of the retort comes from combustion of carbonaceous materials as compared with the quantity of heat from the burner and eventually the combustion in the retort becomes self sustaining. At this point the burner can be turned off and withdrawn from the hole and retorting conducted in the normal manner with air or other gas passed down the hole 13.
Although but a single embodiment of this invention has been described and illustrated herein, many modifications and variations will be apparent to one skilled in the art. Thus, for example, the relative proportions of the elements of the burner can be modified appreciably to provide for combustion of gas having a lower fuel value than the butane-propane mixture for which the illustrated burner was designed. In such a case it may be desirable to bring a larger volume combustible gas supply to the annulus between the outer feed tube and inner feed tube and bring the air through the inner feed tube. Similarly, it will be apparent that if a substantial area of retort is involved it may be preferable to have a plurality of bore holes to the top of the rubble pile so that ignition is obtained at several points and the distance for lateral propagation of the flame front in the retort is minimized. Techniques other than the described reaming may be used for forming the plenum at the top of the rubble pile. Many other modifications and variations will be apparent to one skilled in the art and it is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described.
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A technique is described for igniting the oil shale rubble pile in an in situ oil shale retort. A gas-air burner is lowered through a hole to a plenum over the oil shale to be ignited. An excess of air is passed through the hole and around the burner so that it is kept cool as the flame from it impinges on the rubble pile and the air also provides oxygen for combustion of carbonaceous material in the shale. Preferably the burner is in a cylindrical housing having a refractory exit nozzle at its lower end so that a hot flame is ejected downwardly. Air is brought to the inlet of the nozzle through an outer feed tube in the housing and coaxial therewith. Combustible gas is introduced through an inner axial feed tube which terminates short of the inlet end of the nozzle in a mixing chamber. A mixing orifice is provided between the mixing chamber and the nozzle for thorough mixing of the gas and inhibition of travel of the flame back into the burner. A pair of ignitors downstream from the orifice ignite the gas mixture and the presence of a flame is detected by an ultraviolet sensor mounted for viewing axially through the inner feed tube.
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RELATED APPLICATION
[0001] The present application claims priority from and the benefit of U.S. Provisional Patent Application No. 62/203,183, filed Aug. 10, 2015, the disclosure of which is hereby incorporated herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to power and signal distribution, and more particularly to distribution from hybrid cables.
BACKGROUND
[0003] Latest developments in technology for delivering power and data in wireless infrastructure use hybrid cables, wherein the term “hybrid cable” is intended to mean a cable that includes both power conductors and one or more fiber optic cords or cables. An exemplary hybrid cable is the HFF cable, available from CommScope, Inc. (Joliet, Ill.). Unlike RF-based systems, a single hybrid trunk cable can be used to power multiple sectors, thereby eliminating multiple runs of RF cable. However, in order to use a single hybrid trunk cable, at some point the trunk cable must transition to hybrid jumper cables. Typically, these are distributed inside an enclosure that transitions the trunk conductor gauge to the jumper conductor gauge and connects the optical fibers in the trunk to the optical fibers in the jumper cables. Currently, transitions are achieved by making connections inside the enclosure, requiring it to be opened, cables to be fed/mated to the enclosure, and power and fiber connections to be made, all in the field (e.g., on the top of cell sites near a remote radio unit (RRU)). This practice can create many issues for installers, including time, safety, connection errors (such as loose power connections and/or poor fiber cleaning), and more opportunity for connector damage.
SUMMARY
[0004] As a first aspect, embodiments of the invention are directed to a transition device for interconnecting a hybrid trunk cable and electronic equipment, comprising: an enclosure having first and second ends; a trunk power connector mounted to the first end of the enclosure; a trunk optical connector mounted to the first end of the enclosure; and a plurality of hybrid jumper cables exiting the second end of the enclosure, each of the hybrid jumper cables including at least two power conductors terminated with jumper power connectors and at least one optical fiber terminated with a jumper optical connector.
[0005] As a second aspect, embodiments of the invention are directed to an assembly comprising: (a) a transition device for interconnecting a hybrid trunk cable and electronic equipment and (b) a hybrid trunk cable. The transition device comprises: an enclosure having first and second ends; a trunk power connector mounted to the first end of the enclosure; a trunk optical connector mounted to the first end of the enclosure; a plurality of hybrid jumper cables exiting the second end of the enclosure, each of the hybrid jumper cables including at least one power conductor terminated with a jumper power connector and at least one optical fiber terminated with a jumper optical connector. The hybrid trunk cable has an optical connector and a power connector, the optical connector of the hybrid trunk cable being connected to the trunk optical connector of the first end of the enclosure, and the power connector of the hybrid trunk cable being connected to the trunk power connector of the first end of the enclosure.
BRIEF DESCRIPTION OF THE FIGURES
[0006] FIG. 1 is a rear perspective view of a transition assembly according to embodiments of the present invention.
[0007] FIG. 2 is a front perspective view of the transition assembly of FIG. 1 .
[0008] FIG. 3 is a front perspective view of the fixture and bundled hybrid jumper cables of the transition assembly of FIG. 1 .
[0009] FIG. 4 is a front perspective view of the panel and mounted thereon the trunk optical connector and the trunk power connector of the transition assembly of FIG. 1 .
[0010] FIG. 5 is a rear perspective view of a hybrid trunk cable with power and optical connectors to be mated with the transition assembly of FIG. 1 .
[0011] FIG. 6 is a front perspective view of the transition assembly of FIG. 1 with the housing removed.
[0012] FIG. 7 is a front perspective view of an alternative array of bundled hybrid jumper cables for a transition assembly according to embodiments of the invention.
[0013] FIG. 8 is a front perspective view of a transition assembly employing the bundled hybrid jumper cables of FIG. 7 .
DETAILED DESCRIPTION
[0014] The present invention is described with reference to the accompanying drawings, in which certain embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments that are pictured and described herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. It will also be appreciated that the embodiments disclosed herein can be combined in any way and/or combination to provide many additional embodiments.
[0015] Unless otherwise defined, all technical and scientific terms that are used in this disclosure have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the below description is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used in this disclosure, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that when an element (e.g., a device, circuit, etc.) is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. In contrast, when an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present.
[0016] Referring now to the drawings, a transition device, designated broadly at 10 , is shown in FIGS. 1 and 2 . The transition device 10 includes an enclosure 12 having a housing 14 with a closed end 16 . A connector plate 18 fits within the open end of the housing 14 and may be secured to the housing 14 with a gasket or other sealing technique. The connector plate 18 (see FIG. 4 ) serves as a mounting location for a trunk power connector 20 of conventional construction and a trunk fiber optic connector 22 (which may be an MPO or multi-fiber connector).
[0017] Referring to FIGS. 1, 4 and 6 , the fixture 24 is mounted at the closed end 16 of the housing 14 , and may be sealed with a gasket, sealing compound, or the like. The fixture 24 is configured to secure four hybrid jumper cables 26 in a substantially aligned array or bundle. Each of the hybrid jumper cables 26 includes two power conductors 28 that terminate in a jumper power connector 30 and one or more optical fibers 32 that terminates in a jumper optical connector 34 . At their opposite ends, the power conductors 28 and the optical fibers 32 of the hybrid jumper cables 26 are connected with the connectors 20 , 22 within the enclosure 12 in a conventional manner (see FIG. 6 ). In the illustrated embodiment, the hybrid cables 26 are bundled together in substantial alignment with a collar 36 some distance from the fixture 24 . Typically, the hybrid jumper cables 26 extend between about 0.5 and 50 meter from the enclosure 12 , with a length of 0.75 meters being more typical.
[0018] Referring now to FIG. 5 , a hybrid trunk cable 40 is illustrated therein. The hybrid trunk cable 40 includes power conductors 42 that are terminated with a power connector 44 and optical fibers 45 that are terminated with an optical connector 46 . The power connector 44 is configured to mate with the trunk power connector 20 of the transition device 10 , and the optical connector 46 is configured to mate with the trunk optical connector 22 of the transition device 10 .
[0019] Typically, the hybrid trunk cable 40 is routed from the base of an antenna tower or similar structure to a location adjacent a piece of equipment (such as an RRU) mounted on the structure, where it can be easily mated to the trunk power connector 20 and the trunk optical connector 22 of the transition device 10 . The power cables 28 of the hybrid jumper cables 26 are then connected to the equipment via the connectors 30 and the optical fibers 32 are connected to the equipment via the fiber optic connectors 34 .
[0020] Those of skill in this art will appreciate that the transition device 10 may take other forms. The enclosure 12 may take a different shape. In some embodiments, the enclosure 12 may be partially or completely filled with a potting compound or resin or the like, or may even be formed by overmolding a compound over the power connector 20 , optical connector 22 and hybrid cables 26 . Other configurations will also be apparent to those of skill in this art.
[0021] Moreover, the power connector 20 and optical connector 22 may be replaced by a hybrid trunk connector that mates with a hybrid trunk connector on the hybrid trunk cable. Also, the power and optical connectors 30 , 34 on the power and optical jumper cables 28 , 32 may be replaced with a hybrid connector.
[0022] Referring now to FIGS. 7 and 8 , an alternative embodiment of a transition device 110 is shown therein. The transition device 110 differs from the transition device 10 in the manner in which the hybrid cables 126 exit the enclosure 112 . In the transition device 110 , a circular multi-cable gland 124 is mounted on closed end of the housing 114 . The hybrid cables 126 are routed from the interior of the enclosure 112 through and away from the gland 124 . A square collar 136 maintains the hybrid cables 126 in a bundled fashion prior to their being broken out into power conductors 128 and optical fibers 132 .
[0023] The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although exemplary embodiments of this invention have been described, 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 claims. The invention is defined by the following claims, with equivalents of the claims to be included therein.
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A transition device for interconnecting a hybrid trunk cable and electronic equipment includes: an enclosure having first and second ends; a trunk power connector mounted to the first end of the enclosure; a trunk optical connector mounted to the first end of the enclosure; and a plurality of hybrid jumper cables exiting the second end of the enclosure, each of the hybrid jumper cables including at least two power conductors terminated with jumper power connectors and at least one optical fiber terminated with a jumper optical connector.
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This application is a continuation of application Ser. No. 07/727,529 filed Jul. 9, 1991, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an information detection apparatus, and more particularly to an information detection apparatus as represented by an encoder used for a displacement information measurement apparatus in measuring dimension, distance or velocity such as measurement control which needs a resolution power in the order of atom (several Å).
2. Related Background Art
In the past, the encoder of this type comprises a reference scale having information on position or angle, and detection means relatively movable with the reference scale to detect information on position or angle. Such an encoder is classified into several types depending on the reference scale and the detection means, such as an optical encoder, a magnetic encoder and an electrostatic encoder.
As an encoder having a resolution power in the order of atom, a parallel displacement detection apparatus is disclosed in Japanese Laid-Open Patent Application No. 62-209302. It uses a basic principle of a scanning tunneling microscope disclosed in U.S. Pat. No. 4,343,993 which permits the observation of information on a sample surface at the atom resolution power.
In the past, such an encoder comprises a scale which is a reference to length and a probe arranged in the vicinity of the scale. Information derived from a tunneling current which flows between the reference scale having a drive mechanism and the probe is processed and encoded.
The probe which detects the tunneling current of the encoder is usually manufactured by a well-known electrolytic polishing method to form a sharp needle. Alternatively, machine polishing may be used.
However, the function of the probe which has the sharpness in the order of atom to detect the tunneling current is a heart of the encoder and the performance of the probe directly affects the performance of the encoder. In order to control and detect the tunneling current in the order of pA or nA which flows between the reference scale and the probe, it is necessary to set the distance between the reference scale and the probe to a very small distance such as several nm. Thus, when acoustic vibration or floor vibration occurs, the probe may contact the reference scale and the tip end of the probe may be broken so that it may no longer have the atom resolution power and permit the measurement in the order of atom.
SUMMARY OF THE INVENTION
It is a first object of the present invention to provide an information detection apparatus which permits the continued detection of information even if a probe is broken by vibration.
It is a second object of the present invention to provide a displacement information measurement apparatus which permits the measurement of displacement information with a higher stability without being affected by vibration.
The other objects of the present invention will be apparent from the detailed description of the embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a configuration of an encoder by the detection of a plurality of tunneling currents, in accordance with one embodiment of the present invention,
FIG. 2 shows a block diagram of a signal processing circuit in FIG. 1,
FIGS. 3, 4 and 5 show waveforms of signals produced in the signal processing circuit,
FIGS. 6A and 6B show a basic principle of forming a probe in the embodiment,
FIG. 7 shows a block diagram of a periphery of a sequence control circuit, and
FIG. 8 shows a control flow chart of the sequence control circuit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a configuration of an encoder in one embodiment of the present invention, and FIG. 2 shows a block diagram which is common to a signal processing circuit A and a signal processing circuit B shown in FIG. 1.
In FIG. 1, an object 101 and an object 102 are arranged such that they can relatively move only laterally (left or right on the drawing).
Two probes 11a and 11b are provided for the object 101. Each of the probes 11a and 11b has a probe cover member 12a or 12b and a fine projection 13a or 13b (a method for forming the fine projection will be explained later) on the surface thereof. For the object 102, reference scales 15a and 15b and probe reproducing electrodes 14a and 14b are formed on sample tables 18a and 18b which are rotated by sample table rotation mechanisms 19a and 19b, respectively. A bias voltage is applied between the tip end of the fine projection 13a or 13b formed at the end of the probe 11a or 11b and the reference scale 15a or 15b, by a bias power supply 21a or 21b, respectively. The tip ends of the fine projections 13a and 13b are close enough to the reference scales 15a and 15b to permit the flow of tunneling currents therebetween.
The tunneling currents 10a and 10b which flow from the fine projections 13a and 13b are applied to the signal processing circuits A and B, converted to voltages by a current-voltage converter 107 shown in FIG. 2, amplified by an amplifier 108 and converted by a logarithm converter 109.
The two probes 11a and 11b are vibrated by probe vibration means 110a and 110b (for example, PZT actuators) in the direction of the relative movement of the objects 101 and 102 at a frequency f and an amplitude d. A probe vibration signal is derived from a rectangular wave 2a having a frequency nf generated by an oscillator 111. It is converted to a triangular wave having a frequency f by a frequency divider 112 and waveform transformers 112a and 112b. It is amplified by an amplifier 114 (signal 2c) and applied to the probe vibration means 110a and 110b. Instead of vibrating the probes 11a and 11b, reference scale vibration means may be provided on the object 102 to vibrate the reference scales 15a and 15b.
In order to keep a mean distance between the probe and the reference scale at a constant level when the objects 101 and 102 are relatively moved laterally (in order to keep a mean tunneling current at a constant level), an output signal from the logarithm converter 109 is detected and a feedback loop is formed by a mean tunneling current setting circuit 115 which produces a difference between the output signal of the logarithm converter 109 and the set value, a low-pass filter 116 and an amplifier 117 so that the mean value of the detected tunneling current is equal to the set value. The distance between the probe and the reference scale is controlled by probe vertical displacement control means 17a or 17b (for example, PZT actuator). A cutoff frequency of the low-pass filter is selected such that it removes a fast modulation component of the tunneling current produced by the lateral vibration of the probe on the reference scale and passes a slow change of the tunneling current due to the skew of the reference scale when the objects 101 and 102 are relatively moved laterally.
A modulation component at the frequency f (2d/p, where p is a pitch of the reference scale) due to the scan of the probe on the reference scale appears in the tunneling current 10a or 10b which flows between the probe and the reference scale, by the vibration of the probe by the probe vibration means 110a or 110b. When the objects 101 and 102 are relatively moved laterally, the modulation components at the frequency f (2d/p) which appear in the tunneling currents 10a and 10b cause phase shifts with respect to the reference signal (for example, probe vibration signal). Since one period of the signal (2π phase shift) corresponds to the relative lateral shift of one unit of the reference scale between the probe and the reference scale, the relative lateral displacement of the objects 101 and 102 can be detected by detecting the phase shift.
The operation of the signal processing circuit of FIG. 2 is explained with reference to FIGS. 3 and 4.
The modulation component at the frequency f (2d/p) which appears in the tunneling current is taken out through the current-voltage converter 107, the amplifier 108, the logarithm converter 109 and the band-pass filter 118 (see 2d), and it is binarized by a binarizing circuit 119 to produce a signal 2e. The amplitude (the gain of the amplifier 114) of the probe vibration signal 2c to be applied to the probe vibration means 110 (110a or 110b) is selected such that d=2p/n is met, and the frequency of the signal 2e is selected to be equal to nf. The signal 2a from the oscillator 111 is frequency-divided by the factor of n by the frequency divider 112 to produce a reference signal, and the signal 2e is separated into two signals 2f and 2g by an analog switch 120.
The signal 2a is separated into two signals 2h and 2i by an analog switch 121 by using the signal 2b as a reference signal.
The signals 2f and 2h are applied to a phase comparator 122, and a phase difference output signal 2j is averaged by an averaging circuit 123 to produce a signal 2k. Each time the phase difference reaches 2nπ (where n is an integer), a zero-crossing point of the phase difference output signal 2k (3a) is detected by a binarizing circuit 124 to produce a pulse (signal 3b), and the pulse is counted by an up/down counter 125 so that a phase difference between the signal 2f and the signal 2h is detected.
A phase shift direction signal or an up/down condition (sign) to be applied to the counter 125 is determined in the following manner. The output signal 2a from the oscillator 111 is applied to a phase shifter 126 and an analog switch 127 to produce a signal 2l which has a 90° phase shift with respect to the signal 2h. The signal 2f and the signal 2l are applied to a phase comparator 128, and a phase difference output signal 2m is averaged by an averaging circuit 129 to produce a signal 2n (3d). The signal 3d is binarized by the binarizing circuits 120a and 120b to produce to phase shift direction signal or the up/down signal 3e to be applied to the up/down counter.
In this manner, the relative lateral displacement of the objects 101 and 102 is detected. The relative displacement signal 3c is produced from each of the signal processing circuits A and B as an encoder output a or b, respectively. When the two signals a and b are normal, the signal a is given a priority so that the measurement output is produced only based on the signal a. Alternatively, the measurement output may be produced based on a mean value of the signals a and b.
In the method of the present embodiment, one period (2π) of phase shift corresponds to one unit of reference scale (for example, lattice-to-lattice distance in an atom arrangement of a crystal lattice), of the relative movement. While it was not explained in the present embodiment, the signals 2g and 2i may processed in the same manner to detect the relative movement.
The signals of the encoder outputs a and b of FIG. 1 are compared. FIG. 5 shows waveforms of signals 3a, 3e and 3c in the signal processing circuits A and B. The reference scales of the same material and the same scale pitch are used for reference scales 15a and 15b formed to face the fine projections 13a and 13b. Accordingly, the encoder outputs a and b are to be the same waveform but the comparison of both waveforms indicates the appearance of non-periodicity in the signals at a position X in the signal processing circuit B, as shown in FIG. 5. This means that, at the position X of the signal processing circuit B, the tip end of the fine projection 13b has become improper as the probe for the encoder of the present embodiment which has the atom resolution power, by the influence of the break by the contact.
The performance of the probe is determined by a probe performance test circuit 200 of FIG. 2. In the test circuit, a change in the tunneling current detected by the probe 104 is converted to an electrical signal by the current-voltage converter 107, the amplifier 108 and the logarithm converter 109, and the modulation component at the frequency f 1 (2d/p) on the output signal of the logarithm converter 109 is taken out by a band-pass filter 201. It is rectified by a full-wave rectification circuit 202, averaged by an integration circuit 203, and the average signal is compared with a signal which is produced by a reference power supply 205 and is a reference to a preset probe performance (that is, a signal which is set to an average value of the modulation component which is constant when the needle is normal), by a comparator 204. When the needle is broken, the detection signal including the modulation component is zero or very weak and the average value of the modulation component is smaller than the reference signal. This change is detected by the comparator to determine the performance of the probe and produce the test output. The break of the tip end of the fine projection 13 (13a, 13b) can be determined based on the test output.
FIG. 7 shows a block diagram of a sequence control circuit for controlling various elements in accordance with the break information, and a flow of signals in the periphery of the control circuit. In FIG. 7, numeral 301 denotes a sequence control circuit, and numeral 304 denotes an analog switch for selecting one of encoder outputs a and b of the signal processing circuits A and B. The sequence control circuit 301 reads in the test outputs from the signal processing circuits and selects the encoder output a by the switch 304 when there is no break in any of the projections or there is break in the projection 13b, and selects the encoder output b when there is break in the projection 13a. The sequence control circuit 301 also generates command signals to control other elements shown in FIG. 7.
The measurement of distance is carried out between the fine projection 13a and the reference scale 15a without interruption even if there is a break in the fine projection 13b, but since the tip end of the probe 11a may be broken some time, it is necessary to reproduce or repair the broken fine projection 13b.
The operation of reproduction (controlled by the sequence control circuit 301) is now explained. In the present embodiment, since it is assumed that the tip end of the fine projection 13b is broken, a reproducing mechanism on the left side of FIG. 1 is used. The encoder mechanism on the right side of FIG. 1 continues the measurement of distance. Alternatively, it may temporarily stop the measurement of distance. Since the fine projection 13b is very close to the reference scale 15b to permit the flow of the tunneling current, the probe 11b is retracted from the reference scale 15b by the probe vertical position control means 17b. The sample table 16b on which the reference scale 15b and the probe reproducing electrode 14b are mounted is rotated by 180° by the sample table rotation mechanism 19b and the rotation mechanism position control means 33b so that the probe reproducing electrode 14b faces the fine projection 13b. The probe 11b having the fine projection 13b at the tip and retracted is approached to the distance which permits the flow of the tunneling current in the probe reproducing electrode 14b. A pulse voltage is applied from the pulse power supply 22b between the fine projection 13b and the electrode 14b to permit the reproduction of the fine projection 13b. After the reproduction of the fine projection, the fine projection 13b is retracted and the reference scale 15b is brought to face the fine projection 13b, and fine projection 13b is approached to the reference scale 15b to permit the flow of tunneling current in the reference scale 15b. In this manner, the broken end of the probe can be reproduced. When the fine projection 13a is broken, the switch 304 is selected so that the projection 13a is processed in the same manner. A control flow chart of the sequence control circuit 301 is shown in FIG. 8.
In accordance with the present embodiment, the broken probe can be reproduced, and the other probe continues the measurement of distance while the broken probe is reproduced. Accordingly, the measurement of distance is done exactly and the reliability of the encoder is improved.
The method for forming the fine projection 13 (13a or 13b) used in the present embodiment is now explained in detail with reference to FIGS. 1 and 6.
The material of the probe reproducing electrode 14 (14a or 14b) of the present invention is a platinum evaporated film. The platinum film was evaporated on a corning 7059 glass substrate by an ion beam sputtering apparatus. The material of the probe 11 (11a or 11b) is tangusten. In order to sharpen the tungsten probe, a conventional electrolytic polishing method was used. A radius of curvature at the tip end of the probe 11 manufactured by the electrolytic polishing was approximately 0.1 μm. Gold was deposited to a thickness of 15 nm on the tip end of the probe 11 by using the ion beam sputtering apparatus. The distance between the tip end of the probe 11 and the probe reproducing electrode 14 was close enough to permit the flow of the tunneling current. Pulses each having a pulse width of 4 μs and a pulse height of 4 volts were applied from the pulse power supplies 22a and 22b to the probe 11 and the probe reproducing electrode 14 to form the fine projection 13 (13a, 13b) shown in FIG. 6b. The size and shape of the formed fine projection 13 were of conical shape having a height of 10 nm and a bottom area of 15 nm 2 . A mechanism of the formation of the fine projection would be that the material is instantly and locally molten by the application of the high voltage pulse, and the molten material is tensioned between the probe and the sample because of the electric field applied between the probe and the sample so that the projection is formed. The material of the probe, the material of the coating of the probe and the material of the probe reproducing electrode are not limited to those described above but they may be appropriately selected. It is preferable that the material of the probe has a lower melting point than that of the material of the probe reproducing electrode.
In the present embodiment, particular pulse height and pulse width are used to reproduce the probe, although proper values may be selected depending on the material of the probe and the material of the probe reproducing electrode.
The encoder of the present invention enables the multiple encoding so that when one tunneling current detection probe is broken during the encoding and cannot encode correctly, the encoding by another tunneling current detection probe is continued. Thus, the long time encoding can be effected in a stable manner. Accordingly, an encoder which is stable over a longer period than the prior art encoder is provided.
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An information detection apparatus is disclosed. A plurality of probes are arranged in the apparatus so as to face a medium which carries an information, Each of the plurality of probes produces a detection signal from the medium. A performance testing device is provided in the apparatus for testing the performance of each of the plurality of probes. A detection device in the apparatus selects the signal from at least one normal probe on the basis of the test result of the testing device and detects the information in accordance with the selected signal. By such the construction in the apparatus, the detection of the information can be continuously effected even if one of the probes is broken.
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BACKGROUND OF THE INVENTION
The present invention relates to the art of petroleum processing and, in particular, to the disposal of harmful and noxious waste products resulting therefrom.
Crude oils are exceedingly complex mixtures, consisting predominantly of hydrocarbons containing sulfur, nitrogen, oxygen, and metals as minor constituents. While it is desirable to recover the hydrocarbon constituents in their pure form, realistically it is very difficult to isolate pure products because most of the minor constituents occur in combination with carbon and hydrogen. Separation of impurities such as those listed above generally requires expenditures of valuable resources such as time, chemicals, energy, and money. Therefore, it is the constant goal of the petroleum processing industry to optimize impurity-removal procedures, equipment, and resources in order to eliminate those impurities which have the most degrading effect on the end products.
Perhaps the most ubiquitous impurity encountered in petroleum processing is sulfur. The presence of sulfur in petroleum products and, indeed, in the crude feedstock itself generally increases the corrosive characteristics thereof, and forms harmful and noxious reaction products upon combustion. In particular, the presence of sulfur-containing compounds reduces the combustion characteristics of gasoline and may render fuel oil unusuable in many places due to local regulation on the amount of sulfur allowed therein. Consequently, at nearly every stage of production measures are taken to either reduce the amount of sulfur or to render the sulfurcontaining compounds inoffensive.
One method for removing sulfur-containing compounds--hydrogen treating of petroleum fractions--has been known since the 1930's. However, it was not until the advent of catalytic reforming, which made inexpensive hydrogen-rich off-gas available, that hydrogen desulfurization developed to commercial level. Presently, hydrogen desulfurization is primarily associated with a catalytic reaction using colbalt molybdate on an alumina carrier. The feedstock is mixed with recycle and make-up hydrogen and heated to 400°-850° F., then charged to a fixed bed reactor at 50-1,500 psig.
Hydrogen treating is now used extensively to prepare reformer feedstock and, to some extent, for catalytic cracking feedstock preparation. It may also be used to upgrade middle distillates, cracked fractions, lube oils, gasolines, and waxes. Hydrodesulfurization, however, is a high energyconsuming process which also requires a supply of hydrogen.
Moreover, a major effluent resulting from hydrodesulfurization is hydrogen sulfide, H 2 S,--a flammable poisonous gas. Even though hydrogen sulfide may simply be burned-off into the atmosphere legislation in recent years has effectively limited this method of disposal because of the formation of sulfur dioxide which is intensely irritating to the eyes and respiratory system. Accordingly, alternative means for disposing of hydrogen sulfide have been developed and implemented.
The primary method of disposing of hydrogen sulfide is to convert the sulfur-bearing gas to elemental sulfur and water by, for instance, the Claus process. While this alternative may appear somewhat attractive since elemental sulfur is a saleable commodity, the Claus process requires construction of sulfur plants, quantities of catalysts, and energy. Furthermore, the market for elemental sulfur is not so extensive as to be able to absorb all the elemental sulfur currently produced without depressing the price therefor. Finally, the Claus process itself is fraught with some difficulty in that approximately 3% of the reaction product is, again, the noxious dioxide which must be further treated by, for instance, a tail gas treating process, in order to reduce the level of SO 2 effluent to within the Environmental Protection Agency standard of not more than 250 parts per million on a dry oxygen-free basis. Consequently, while the Claus process is still a viable alternative for disposing of hydrogen sulfide gas, it has become less attractive because of the cost of carrying out the process and because of the decrease in demand for the elemental sulfur.
Another method for treating petroleum to reduce the degrading effects of sulfur is chemical processing to "sweeten" sulfur compounds contained in the particular fractions, e.g., the mercaptans which are designated by the formula RSH. "Sweetening" denotes that mercaptan sulfur compounds are removed from a refinery stream, or else the mercaptans are converted to less objectionable disulfide compounds, e.g., R-S-S-R, R-S-S-R', etc. A particularly important process employed today is the sweetening of kerosine by the MEROX process to obtain jet fuel.
Whether sweetening is undertaken by solvent refining processes or by fixed bed adsorption, a caustic solution is generally first used to convert the mercaptan to the ionic state, RS - . Caustic solution is also helpful in that it removes napththenic acids and other organic acids in general, and other sulfur compounds from cracked petroleum products and petroleum distillate. In fact, caustic treating of petroleum products has been used to improve odor and color nearly as long as the industry itself has been in existence. Numerous equipment modifications and processes have been designed to implement caustic treatment of process streams. Unfortunately, since caustic is quite harmful to organic tissue extreme care must be taken in the use and disposal of alkaline solutions such as sodium hydroxide solutions in order to protect the waterways, rivers, subterranean water formations, and, in many places, the oceans and surrounding seas of industrial areas from caustic pollution. This presents a significant problem to the industry because of the great volume of caustic used in petroleum processing and because all of the solutions used must eventually be discarded as a nonregenerative caustic or as the spent liquor resulting from a regenerative process.
To date, the industry generally uses two methods to dispose of spent caustic--neutralization and incineration, incineration being a relatively new trend in waste alkaline liquor disposal. Incineration disposal presents certain advantages over neutralization disposal in that it is, first of all, environmentally cleaner since acid neutralization has a residual OOD (Organic Oxygen Demand) for the naphthenic acids. Other advantages include such benefits as lower capital investment and less operating space required (i.e. ground area). Furthermore, incineration disposal is easier to operate. On the negative side, cost of operation of the incinerator units is high because of the energy required to maintain the elevated temperatures necessary to maintain combustion of the predominantly aqueous solution of alkaline waste. Commercial units presently in operation make use of the combustion of fuel oil, and natural gas to sustain the evaporation of the aqueous parts of the waste liquor and then furnish mostly carbon dioxide, CO 2 , to form the innocuous carbonates of sodium or other alkali metals for disposal. Refined fuel oil, and natural gas are very expensive means for disposing of the volumes of caustic discarded as a result of petroleum processing and they are both very valuable commodities in terms of consumer-useable energy sources.
From the foregoing discussion, it can be seen that the elimination of sulfur from petroleum presents several problems including, inter alia, production of alkaline waste liquor and hydrogen sulfide, both of which require either energy and/or expensive treatment to convert them to environmentally safe substances. It is, therefore, a primary purpose of the present invention to provide a process whereby the great volume of alkaline waste liquor which results from petroleum processing can be safely disposed of without expending commercially useable and expensive fuel supplies.
Another object of this invention is to provide a process for the formation of innocuous products from potentially harmful and/or noxious sulfur-containing fuels.
SUMMARY OF THE INVENTION
By the present invention, it is proposed to provide a method for treating alkaline effluents generated during petroleum processing consisting essentially of incinerating those effluents in the presence of oxygen and a sufficient quantity of sulfur-containing fuel to convert the alkaline material, which is normally spent caustic to the corresponding sulfate. In a preferred embodiment of the present invention the sulfur-containing fuel is hydrogen sulfide, H 2 S, which may be derived from any hydrogen-sulfide-producing process such as hydrodesulfurization. The combustion temperature at which the alkaline effluent is incinerated is preferably about 1250° C.
The combustion of hydrogen sulfide provides the heat necessary to initiate combustion of organic compounds in the waste, and it provides oxides of sulfur to neutralize the caustic by formation of innocuous compounds, e.g., Na 2 SO 4 , K 2 SO 4 , etc.
For a better understanding of the present invention, together with other and further objects, reference is made to the following description taken in conjunction with the accompanying drawings, and its scope will be pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of the process of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The process of the present invention is based on the principle that an alkaline compound is capable of reacting with a sulfur-containing fuel in the presence of oxygen to form a harmless sulfate. Stoichiometrically, the typical reaction proceeds according to the following equations:
21/2O.sub.2 +H.sub.2 S+2Na.sup.+ →Na.sub.2 SO.sub.4 +H.sub.2 O (1)
21/2O.sub.2 +H.sub.2 S+2K.sup.+ →K.sub.2 SO.sub.4 +H.sub.2 O (2)
Referring to the drawing, the above-described conversion reaction takes place in a refractory incinerating column 10, into which the different components are fed by means of metered flow stream lines as described herein.
In a preferred embodiment of the invention, the fuel used to support the combustion reaction is hydrogen sulfide gas, H 2 S, which may be derived from hydrodesulfurization processes. Pure H 2 S is not required but rather various H 2 S-containing refinery streams can be used. This form of the process is especially attractive since the combustion of gas is easier than the combustion of a liquid sulfur-containing fuel, such as fuel oil. In the drawing, fuel input is designated by feed line 12 which supplies the fuel to the top portion of the column. Additionally, a fuel supply line, shown as phantom feed line 14, may be installed to provide an alternate supply of sulfur-containing fuel to be used in addition to or in lieu of the previously-indicated source. If the alternate supply of sulfur-containing fuel is in a physical state different than the physical state of the primary source, e.g., liquid fuel oil vs. gaseous hydrogen sulfide, then a separate metering device should be used on the additional fuel supply line, as is depicted herein, in order to facilitate maintenance of the correct stoichiometric amount of sulfur to sustain the described reactions.
The other primary reaction product and the most important waste product that must be disposed of is the alkaline waste liquor. Preferably, this waste liquor is first collected in a repository 16 from the various sources in the petroleum processing system wherein spent caustic is generated. The alkaline solution, which is predominantly aqueous in nature, is then pumped to the incinerator unit over alkaline supply line 18 into which pressurized air is injected via air feed line 20 prior to introduction into the incineration chamber. Pressurized air is needed to atomize the aqueous alkaline solution so that the aqueous content and the alkaline material is finely dispersed to facilitate rapid reaction.
The final reaction component that must be provided for the conversion of waste caustic and hydrogen sulfide fuel to the innocuous sulfate is oxygen. Besides the oxygen which is provided to atomize the caustic or to atomize a liquid fuel if, for instance, fuel oil is used as an auxiliary fuel, oxygen should also be provided by, for example, a separate air supply line 22 in a sufficient quantity to insure total combustion of the alkaline material in the spent waste liquor, as well as any organic compounds that may be formed in the waste liquor. Additional air may be provided via subsidiary air supply line 24 to the input of the waste caustic solution to insure that the solution is adequately dispersed for complete burning.
Once the combined fuel, oxygen and caustic is ignited, continual combustion is sustained by the heat of the described reaction and normal rapid oxidation of the components found in the waste caustic/fuel mixture. Combustion of organic compounds present in the waste liquors aid in the heat balance of the incinerator, form CO 2 as a combustion product, and generate carbonate salts of the alkali metals.
Furthermore, every mole of hydrogen sulfide combusted supplies one mole of H 2 for the generation of H 2 O, which is also needed in the maintenance of the mass and heat balances of the incinerator.
To be sure certain advantages accure to the process wherein the gaseous H 2 S is used as the fuel. Control of the fuel to air to waste liquor ratio of a gaseous fuel is easier than controlling that of a heavier viscuous fuel oil, especially if changes in the nature of the alkali metal ions content is anticipated. Furthermore, H 2 S contains 94% sulfur and thus furnishes a constant sulfur content for much operation.
However, it is still within the scope of the present invention to include the use of sulfur-containing fuel oil as an auxiliary fuel to support continual conversion reaction. This option becomes particularly attractive when the crude stock is exceptionally sour (i.e. high in sulfur content) thereby requiring extensive hydrodesulfurization to obtain a fuel oil which is saleable in those parts of the country that require the use of a relatively sulfur-free fuel oil for industrial and domestic heating. Hydrodesulfurization, however, is an energy intensive process that requires a constant supply of hydrogen. Instead of processing the fuel oil fraction to the extent required to eliminate nearly all the sulfur-containing compounds found therein, it may well be discovered upon cost analysis that a savings would be realized by burning the high-sulfur-content fuel oil in the process described by the present invention to render the caustic effluents harmless.
Regardless of the auxiliary fuel, the principle of the present invention reamins the provision of a hydrogen sulfide as a fuel to incinerate an alkaline solution thereby producing a harmless sulfate, and, while a particular arrangement of apparatus is schematically shown herein as a system for implementing this process, the inventors do not concede this to be in any way a limiting depiction of the myriad of arrangements which could be used to perform the novel process.
While there have been described what are believed to be the preferred embodiments of the invention, those skilled in the art will realize that changes and modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such changes and modifications as fall within the true scope of the invention.
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The present invention is a method for treating alkaline effluents resulting from petroleum processing by incinerating the effluents in the presence of oxygen and a sufficient amount of hydrogen sulfide fuel to convert the alkaline material to the corresponding sulfate.
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This application claims the benefit of U.S. Provisional Application Ser. No. 60/055,980, filed on Aug. 18, 1997, which provisional application is incorporated by reference herein.
TECHNICAL FIELD
The invention relates to combination locks. More particularly, the invention relates to combination locks that accommodate combination changes by lock users.
BACKGROUND
Combination locks are quite common, and all mechanical ones operate in the same basic fashion. A graduated dial, typically scaled from 1 to 100, rotates a spindle that in turn rotates a drive cam. A bushing supports a series of tumblers, one of which is a drive tumbler connected to the drive cam. The drive cam drives the drive tumbler so that, when a user selects a series of combination numbers with the dial, the driven tumblers are aligned to allow operation of a door handle or lock hasp or the like. In door locks, each tumbler has a gate notch in its periphery situated such that when the notches of all of the tumblers are aligned, a stop on a door handle can travel, allowing operation of the door handle. Most combination locks have only one operative combination that is not easily changed. As a result, if the combination is compromised, a new lock with a different combination would have to be purchased, or the lock would have to be disassembled to change the combination.
In response to a desire for more flexibility and security in combination locks, changeable combination locks have been developed. Most changeable combination locks have some arrangement allowing realignment of the drive system and the tumbler gate notches to alter the combination. For example, one prior art changeable combination lock uses two-part tumblers. Inner tumblers carry teeth on their peripheries that engage teeth on the inner peripheries of outer tumblers. The outer tumblers also carry gate notches on their outer peripheries that allow use of a door handle when aligned. The inner tumblers can be disengaged from the outer tumblers to allow relative rotation for resetting the combination. To change the combination, a user throws the lock bolt out and then inserts a wire into the lock to allow relative movement of the inner and outer tumblers. The lock spindle is then pressed inward to disengage the inner tumblers from the outer tumblers, at which point the combination can be changed. This arrangement includes many steps and parts that increase the complexity of the lock. Also, the requirement of extra tools, such as a wire, to change the combination is inconvenient to the user.
Another prior art changeable combination lock includes a wave or disc spring mounted between an inner wall of a safe door and the immediately adjacent tumbler. The spring biases the tumblers against the drive cam. To change the combination of the lock, the user first removes the back panel of the lock, dials the combination to align the notches, and then holds the door handle in place to hold the notches in alignment. While holding the handle, the user pushes against the drive tumbler to disengage the drive tumbler from the drive cam. Still holding the handle and pushing against the drive tumbler, the user rotates the dial of the lock by a desired increment so that the drive cam engages the drive tumbler at a new point, thus changing the alignment point of all the tumblers by the increment the dial has been rotated. The handle and drive tumbler can then be released, and the lock can be used with the new combination. This lock is easier to use, but requires the user to do too many things at once and does not provide an easy way to disengage the drive cam and drive tumbler.
In view of the prior art, there is a need for a changeable combination lock that is simple in its construction and easy to use. The lock should allow the user to perform relatively few simple steps to change the combination of the lock.
SUMMARY OF THE INVENTION
My new changeable combination lock uses a clutch between the lock spindle and the drive tumbler for easy disengagement. An actuator of the clutch extends into and can protrude from the rear panel of the door or lock for easy access and operation of the clutch by a user from outside the door and without additional tools. The clutch severs the drive connection between the spindle and the drive tumbler so that the user can rotate the knob and spindle relative to the drive tumbler to change the combination. Because the clutch actuator is accessed through the rear panel of the door, the user does not need to remove the panel to change the combination.
More particularly, a first embodiment of my new lock can use a spring-biased combination changer. In this embodiment, the user opens the safe, leaving the handle in an open position to hold the tumbler notches in alignment. The user then presses a button in or protruding from the inside of the door and rotates the combination lock dial by a desired amount. After the user releases the button, the safe can be used with the new combination. This embodiment of my lock is advantageous over the prior art locks because the user need only press a button to disengage the drive cam from the driver rather than removing the back panel of the safe door and pressing on the drive tumbler itself. This embodiment of my lock is also an improvement over locks using multi-part tumblers because my tumblers are very simple.
Alternatively, my invention includes a thumbscrew that holds the drive cam in a disengaged state. Thus, to change the combination of my new lock, the user dials the combination, holds the door handle down, disengages the clutch with the thumbscrew, rotates the dial by a desired amount, reengages the clutch, and can then operate the lock with the new combination. This is a marked improvement over the prior art locks that require the user to remove the rear panel of the door and then hold a spring-biased drive tumbler in a state of disengagement while holding the door handle down and rotating the lock dial. Also, as with the first described embodiment, my lock is an improvement over locks using multi-part tumblers because my tumblers are very simple.
While my new lock can be used in any suitable device, it is intended for use in safe doors. My lock is particularly suited for use in insulated steel shell safes.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of a safe door including the changeable combination lock of the invention.
FIG. 2 is a rear perspective view of the safe door of FIG. 1.
FIG. 3 is a rear perspective view of the safe door of FIG. 1 with the rear panel removed.
FIG. 4 is a cross section of the safe door of FIG. 1 taken along line 4--4 where the door includes a first embodiment of the lock of the invention.
FIG. 5 is a detail of a cross section of the safe door of FIG. 1 taken along line 4--4 where the door includes a second embodiment of the lock of the invention.
FIG. 6 is a cross section of the safe door of FIG. 1 taken along line 6--6 showing the handle and its associated components in the safe door.
DETAILED DESCRIPTION OF THE INVENTION
As seen in FIGS. 1-3, a door 1 for a steel shell safe (not shown) includes a front door plate 2, a jamb 3 attached to the back of door plate 2, and a hinge 4. A combination lock 5, a key-operated lock 6, and a handle 7 can be mounted on the door 1. Insulative material 8 fills the space between the front door plate 2 and the jamb 3. The preferred insulation 8 is concrete heavily laden with water.
As is known in the art, combination lock 5 includes a rotatable knob 10 mounted on the exterior of the door 1. With particular reference to FIGS. 4 and 5, the knob 10 is preferably insert molded onto a forward end of a spindle 11 that extends through the door 1. The inner or rearward region of the spindle 11 is in turn connected to a series of tumbler discs 12 via a driver 13. The tumbler discs 12 are rotatably mounted coaxially with the spindle 11 on the back of the door 1. The driver 13 retains, engages, and drives the tumbler discs 12 about the combination lock spindle 11 so that they can be operated to selectively lock and unlock the safe. The tumblers 12 carry gate notches 14 in their peripheries that are aligned when the combination is dialed.
The handle 7, as shown in FIG. 6, is attached to a spindle 30 that operates a live bolt system 31 mounted on the interior surface of the door 1. When the gate notches 14 are aligned and the handle 7 is rotated, the handle spindle 30 also rotates causing the live bolts 32 of the live bolt system to move into or out of a locked position.
The combination lock spindle 11 and handle spindle 30 are each supported by respective bushings 40, 42 in pass-through tube portions 80, 82 that pass from the back of front door plate 2 to the jamb 3. The tube portions 80, 82 preferably have supporting ribs 43 arranged around their outer surfaces and extending into the insulation 8 for extra support. The inner surface 44 of a forward region of the combination lock bushing 40 provides a running fit for the knob 10.
Inner end or rearward portions 50, 51 of the bushings 40, 42, respectively, extend from a forward region of the door 1 to a rearward region of the door 1. The rearward portions 50, 51 preferably extend beyond the rear wall 9 of the jamb 3 to form stub or sleeve portions 52, 53. The outer surfaces 47, 48 of stubs 52, 53 are preferably substantially cylindrical and support components of the combination lock 5 and live bolt system 31.
Stub portion 52 rotatably supports a drive tumbler 12a and additional driven tumblers 12b, 12c, 12d on its outer surface. The drive cam 13 carries thereon a number of teeth 90 that engage corresponding teeth 91 provided on the drive tumbler 12a such that the drive cam 13 rotates the drive tumbler 12a. The mutually engaging teeth 90, 91 can be of any suitable form, but are preferably saw teeth or pegs with corresponding holes. A disengagement mechanism or clutch 100 is interposed in the drive train such that it can selectively disengage the drive tumbler 12a from the drive provided by the combination lock spindle 11.
In a second embodiment of the invention, the drive cam 13 is mounted on the end of the spindle 11 for conjoint rotation therewith. The drive tumbler 12a is longitudinally slidable and is preferably biased against the drive cam 13 by a spring 114, such as a conical spring. The disengagement mechanism 100 is a cup 130 that preferably sits over and has a larger diameter than the drive cam 13. The cup 130 engages the drive tumbler 12a with teeth 94 that mesh with corresponding teeth 95 on the drive tumbler 12a. Thus, the teeth 94, 95 are mutually engaging teeth of the cup 130 and the drive tumbler 12a. In the preferred form of this embodiment, the cup 130 and the drive tumbler 12a are always in a state of engagement and rotate conjointly. The cup carries a button 131 that extends into the rear panel 120, preferably with its rearwardmost surface flush with the rear surface of the rear panel 120 for easy access. The button 131 can also be designed to protrude beyond the rear panel 120 of the lock, allowing easier access to the button 131 but increasing the risk that the button 131 will be depressed accidentally. When depressed, the button transmits force to the cup 130 which transmits the force to the drive tumbler 12a. Application of enough force to overcome the bias on the drive tumbler 12a causes the drive tumbler 12a to disengage the drive cam 13. When the drive tumbler 12a and the drive cam 13 are disengaged, the drive cam 13 can rotate freely with respect to the drive tumbler 12a and the cup 130.
To change the combination, the user dials in the combination with the lock knob 10 and opens the safe with the handle 7. Leaving the handle 7 down to hold the drive and driven tumblers 12 in place, the user presses the button 131 to disengage the drive tumbler 12a from the drive cam 13 and then rotates the lock knob 10 by a desired increment as indicated on the scale 101. The drive cam 13 rotates relative to the drive tumbler 12a so that the alignment position of the tumbler gate notches corresponds to the old combination plus the increment dialed by the user. The user then releases the button 131 to reengage the drive tumbler 12a and drive cam 13 and can then operate the safe with the new combination. The entire process is done without using any tools and without removing the rear panel 120 of the combination lock 5.
The number of teeth on the drive cam 13 need not be the same as the number of teeth on the drive tumbler 12a. One of these parts should carry a number of teeth that is a whole number factor of the maximum number of the dial scale 101. In other words, if the scale 101 has numbers from 1-100, the number of teeth on one of the drive tumbler 12a or the drive cam 13 should be a factor of 100. The teeth 90, 91, 94, 95 of all parts of this embodiment can be of any suitable type, but are preferably pegs that meet corresponding holes.
In a second embodiment of the invention, the disengagement mechanism 100 is the drive cam 13, which comprises an upper drive cam 13a and a lower drive cam 13b. A sleeve 15 on the upper drive cam 13a engages the outer surface of the interior end of the combination lock spindle 11 so that the upper drive cam 13a rotates with the spindle 11. Preferably, the outer surface of the spindle 11 and the inner surface of the sleeve 15 have square cross sections to better ensure conjoint rotation of these parts.
The lower drive cam 13b carries the teeth 90 that engage and drive the drive tumbler 12a via corresponding teeth 91 on the drive tumbler 12a. Thus, the teeth 90 and the teeth 91 are mutually engaging teeth of the lower drive cam 13b and the drive tumbler 12a. The lower drive cam 13b also carries a set of teeth 92 engaging corresponding teeth 93 on a lower portion of the upper drive cam 13a. Thus, the teeth 92 and the teeth 93 are mutually engaging teeth of the upper and lower drive cams 13a, 13b. A bearing or bushing 16 permits relative rotation between the lower drive cam 13b and the lock spindle 11, though the lower drive cam 13b can simply slide against the lock spindle 11 if a bearing or bushing 16 is not used.
Upper drive cam 13a carries in its center a coaxial adjusting screw 111, preferably a thumb screw that can be adjusted without tools. One end of the screw 111 is mounted in a threaded bore 112 in the interior end of the spindle 11, the other end of the screw extending into and/or protruding from the rear panel 120 of the lock 5 or the door 1. The spindle end of the screw 111 carries threads 115 that mesh with the threads of the spindle bore 112, causing relative axial movement between the screw 111 and the spindle 11 when the screw 111 is rotated relative to the spindle 11. Shoulders or snap rings 113 on the screw on either side of the upper drive cam 13a prevent longitudinal movement of the screw 111 relative to the upper drive cam 13a.
The drive cams 13a, 13b and the thumb screw 111 effectively form the clutch 100 in the knob/drive tumbler drive train, with the screw 111 acting as an actuator for the clutch. Unscrewing the screw 111 moves the upper drive cam 13a out of engagement with the lower drive cam 13b, permitting relative rotation between the spindle 11/upper drive cam 13a and the lower drive cam 13b/drive tumbler 12a.
In operation of the second embodiment, the user first dials the combination of the lock 5 using the knob 10, then operates the handle 7 to open the door 1. Leaving the handle 7 down, the user rotates the screw 111 to disengage the upper cam 13a from the lower cam 13b. The user then rotates the lock knob 10 by a desired increment to change all of the numbers of the combination by the increment as shown on the scale 101 of the knob 10. The user then screws the upper cam 13a back into engagement with the lower cam 13b and operates the safe with the new combination. The entire process requires no tools and can be done without removing the rear panel 120 of the combination lock 5 or door 1.
The number and size of the increments available to the user is fixed upon manufacture, but can be varied in the design of the drive cam assembly by changing the number of teeth 92, 93 on the upper and lower drive cams 13a, 13b. Preferably, the size of the increments is a whole number factor of the scale 101 of the safe dial. For example, if the scale were 1-100, 20 teeth would yield increments of 5. The number of teeth 92, 93 on the upper and lower drive cams 13a, 13b does not need to be the same. In such a design, the number of teeth on the drive cam with more teeth determines the increment size. The teeth 90, 91, 92, 93 of all parts of this embodiment can be of any suitable type, but are preferably saw teeth or pegs that fit in corresponding holes.
Parts list
1 Door
2 Front door plate
3 Jamb
4 Hinge
5 Combination lock
6 Key lock (key-operated day lock)
7 Handle
8 Insulative material
9 Rear wall of jamb
10 Knob or dial of combination lock
11 Lock spindle (combination lock spindle)
12 Tumblers (tumbler discs)
12a Drive tumbler
12b-d Driven tumblers
13 Driver (tumbler driver) or drive cam
13a Upper drive cam
13b Lower drive cam
14 Gate notch
15 Drive cam sleeve
16 Bearing or bushing of lower drive cam
30 Handle spindle
31 Live bolt system
32 Live bolts
40 Combination lock bushing
42 Handle bushing
43 Ribs
44 Inner surface of combination lock bushing
47 Outer surface of combination lock bushing
48 Outer surface of handle bushing
50 Inner end portion of combination lock bushing
51 Inner end portion of handle bushing
52 Stub or sleeve portion of combination lock bushing
53 Stub or sleeve portion of handle bushing
80 Tube portion of combination lock bushing
82 Tube portion of handle bushing
90 Teeth of drive cam engaging drive tumbler
91 Teeth on drive tumbler engaging drive cam
92 Teeth of lower drive cam engaging upper drive cam
93 Teeth of upper drive cam engaging lower drive cam
94 Cup teeth engaging drive tumbler
95 Drive tumbler teeth engaging cup
100 Disengagement mechanism or clutch
101 Scale of lock knob or dial
111 Screw of clutch in upper drive cam
112 Threaded bore hole in combination lock spindle
113 Shoulders or snap rings on screw
114 Spring biasing drive tumbler
115 Clutch screw threads
120 Rear panel of combination lock or door
130 Cup over drive cam and engaging drive tumbler
131 Button on clutch
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A combination of the inventive combination lock can be easily and conveniently changed by the user. A clutch selectively disengages the drive tumbler from the lock spindle. With the drive tumbler disengaged and the tumblers in an aligned position, the user rotates the lock knob by a desired increment, thereby changing all of the numbers by the increment. In one embodiment, the clutch is operated by a cup mounted around the drive cam and engaging the drive tumbler, a spring biasing the drive tumbler against the cup and the drive cam, and the cup carrying a button that, when pressed, moves the drive tumbler out of engagement with the drive cam. In another embodiment, the clutch is operated by a thumb screw projecting through a rear panel of the combination lock that moves an upper part of the drive cam out of engagement with a lower part of the drive cam, allowing relative rotation of the lock dial and the drive tumbler.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority of U.S. Provisional Patent Application Ser. No. 60/682,520 filed May 18, 2005 entitled “Utilization of solar energy with textile heat accumulators”.
BACKGROUND OF THE INVENTION
[0002] The worldwide increase in energy demands, the constant rise in energy prices and concerns of environmental damages caused by the increased use of fossil energy resources drives the demand for energy conservation and the use of renewable energies. The problem can be solved by the implication of textile heat accumulators based on the application of phase change material and used for hot water supply.
[0003] Phase change material is a highly-productive thermal storage medium which possesses the ability to change its physical state within a certain temperature range. When the melting temperature is obtained during a heating process, the phase change from the solid to the liquid state occurs. During this melting process, the phase change material absorbs and stores a large amount of latent heat. The temperature of the phase change material remains nearly constant during the entire process. When the phase change is complete, a continuing heating process leads to a further temperature increase and the absorption of a much smaller amount of sensible heat. In a cooling process of the phase change material, the stored latent heat is released into the environment in a certain temperature range, and a reverse phase change from the liquid to the solid state takes place. During this crystallization process, the temperature of the phase change material also remains constant. The high heat transfer during the melting process and the crystallization process, both without any temperature change, is responsible for the phase change material's appeal as a source of heat storage.
[0004] In order to contrast the amount of latent heat absorbed by a phase change material during the actual phase change with the amount of sensible heat absorbed in an ordinary heating process, the ice-water phase change process will be used. When ice melts, it absorbs an amount of latent heat of about 335 J/g. When the water is further heated, it absorbs a sensible heat of only 4 J/g while its temperature rises by one degree C. Thus, water needs to be heated as long as its temperature rises from 1° C. to about 84° C. in order to absorb the same amount of heat which is absorbed during the melting process of ice.
[0005] In addition to ice (water), more than 500 natural and synthetic phase change materials are known. These materials differ from one another in their phase change temperature ranges and their latent heat storage capacities.
[0006] Currently, crystalline alkyl hydrocarbon phase change materials having different chain lengths are used in textile applications and more specifically in garment applications. Characteristics of these phase change materials are summarized in Table 1.
TABLE 1 Crystalline alkyl hydrocarbons Latent heat Crystalline Melting Crystallization storage alkyl temperature, temperature, capacity, hydrocarbons Formula ° C. ° C. J/g Heneicosane C 21 H 44 40.5 35.9 213 Eicosane C 20 H 42 36.1 30.6 247 Nonadecane C 19 H 40 32.1 26.4 222 Octadecane C 18 H 38 28.2 25.4 244 Heptadecane C 17 H 36 21.7 16.5 213 Hexadecane C 16 H 34 16.7 12.2 237
[0007] The crystalline alkyl hydrocarbons are either used in technical grades with a purity of approximately 95%; or they are blended with one another in order to cover specific phase change temperature ranges. The crystalline alkyl hydrocarbons are nontoxic, non-corrosive, and non-hygroscopic. The thermal behavior of these phase change materials remains stable under permanent use. Crystalline alkyl hydrocarbons are byproducts of petroleum refining and, therefore, inexpensive. A disadvantage of crystalline alkyl hydrocarbons is their low resistance against ignition.
[0008] Salt hydrates are alloys of inorganic salts and water. The most attractive properties of salt hydrates are the comparatively high latent heat storage capacities, the high thermal conductivities and the small volume change during melting. They are mostly non-combustible which makes them specifically attractive for building applications. Salt hydrates often show an incongruent melting behaviour as a result of a lack in reversible melting and freezing making them unsuitable for permanent use. Salt hydrates with reversible melting and freezing characteristics are summarized in Table 2.
TABLE 2 Salt hydrates Latent Melting heat storage temperature, capacity, Salt hydrates ° C. J/g Calcium cloride hexahydrate 29.4 170 Lithium nitrate trihydrate 29.9 296 Sodium hydrogen phosphate dodecahydrate 36.0 280 Sodium thiosulfate pentahydrate 49.0 200 Lithium acetate dihydrate 56.0 270 Magnesium cloride tetrahydrate 58.0 180
[0009] Phase change materials have been suggested for the use in solar energy systems. For instance, U.S. Pat. No. 5,269,851 describes a solar energy system where phase change material is used to protect photovoltaic cells from excessive temperatures.
[0010] U.S. Pat. No. 5,505,788 reports a photovoltaic roofing assembly where phase change material is used for temperature regulation.
[0011] Furthermore, phase change material is used for intermediate heat storage in a water heating unit described in U.S. Pat. No. 6,047,106.
SUMMARY OF THE INVENTION
[0012] The invention pertains to a textile heat accumulator consisting of a textile composite with incorporated phase change material which is suitable for energy storage as well as hot water generation. The textile heat accumulator is preferably used in roofs of residential or commercial buildings. In its building application, the textile heat accumulator controls the heat flux into the building. In addition, the latent heat stored in the phase change material during the day is used for hot water supply. The phase change material is integrated into an elastomeric compound which is applied to a carrier fabric in form of a coating. The textile carrier is equipped with capillary pipes which are used for water transportation. In order to use the stored latent heat, cold water is pumped through the capillaries. The water absorbs the latent heat stored in the phase change material, heats up and can be used as hot water. The textile composite replaces the heat storage unit of common thermal solar energy systems. Comparing the proposed system to the common thermal solar systems, the proposed system is less expensive and does not require a lot of space. Furthermore, by recharging the phase change material during the day, the thermal performance of the phase change material is enhanced significantly.
[0013] In a preferred embodiment of the technique of the present invention, the phase change materials are non-combustible salt hydrates which allows them to meet fire-resistance requirements of building materials.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a sectional view of the textile heat accumulator.
[0015] FIG. 2 is a sectional view of a roof structure which contains the textile heat accumulator.
[0016] FIG. 3 is a schematic diagram of a hot water generation embodiment where the textile heat accumulator represents the storage unit.
DETAILED DESCRIPTION OF THE INVENTION
[0017] In accordance with the present application, and with reference to FIG. 1 the textile heat accumulator of the present invention includes a first layer ( 1 ), a second layer ( 3 ) and a third layer ( 4 ). The first layer is an elastomeric coating compound comprising finely divided phase change materials. The second layer is a fabric which has capillary pipes ( 2 ) attached to one of its sides. The third layer is another coating compound which does not include phase change material.
[0018] In a preferred embodiment of the textile heat accumulator, the phase change material used within absorbs latent heat when its temperature rises above 55° C.
[0019] Most preferably, the phase change material used in the textile heat accumulator is a non-combustible salt hydrate. Using a non-combustible salt hydrate in the technique of the present invention allows for compliance with fire-resistance requirements of building materials. For instance, lithium acetate dihydrate and magnesium cloride tetrahydrate are suitable phase change materials for an application in the textile heat accumulator.
[0020] Crystalline alkyl hydrocarbons might be used in the technique of the present invention in conjunction with flame-retardant additives. For instance, mixtures of tetracosane and hexacosane are suitable crystalline alkyl hydrocarbons phase change materials for an application in the textile heat accumulator.
[0021] The selected salt hydrate or crystalline alkyl hydrocarbon can be durably contained in an elastomer whereby the phase change materials are cross-linked into the elastomer's structure. Finely-divided phase change materials emulsified or dispersed in the elastomer's structure do not flow out of the elastomer structure while in a liquid stage. The composition remains stable under substantial temperature variation over a long service life.
[0022] Such elastomeric materials can comprise, by way of example and not by limitation silicone rubber, acrylate rubber, butyl rubber, nitrile rubber or chloroprene rubber. Furthermore, thermoplastic elastomers with, for instance, fluorine, polyurethane or polyester as basic components are also suitable containment structures for the phase change material application.
[0023] In the manufacturing of the textile heat accumulator with incorporated phase change material, the phase change material is thoroughly mixed into the components creating the elastomeric matrix. Then, the elastomeric compound with the phase change material incorporated therein can be topically applied to the carrier fabric by knife coating; and there, the system will be cured. The phase change materials may be incorporated into the elastomeric matrix in a weight portion of up to 60 wt. % based on the material's total weight.
[0024] Most preferably, the carrier fabric used in the textile heat accumulator arrangement consists of a spacer fabric, a woven fabric, a non-woven fabric or a knitted fabric. The carrier fabric provides mechanical stability to the composite and creates a carrier for the elastomeric coating compound with the incorporated phase change material. Capillary pipes are attached to one side of the fabrics surface's and fixed thereof. The pipes are arranged on the fabric surface in a parallel structure with a given distance between each other. For instance, an area of 1 m 2 contains about 80 pipes with diameters of about three millimetres. The elastomeric compound with the phase change material is applied to the fabric's surface to which the pipes are attached to. It surrounds the capillary pipes completely, i.e. the pipes are embedded in the elastomeric compound. However, the pipe openings on the two small sides of the fabric are open so that water can flow through the pipes. The back side of the carrier fabric is covered with a coating layer which does not contain phase change material, in order to protect the surface against mechanical distraction and moisture.
[0025] In a preferred embodiment of the present invention, the textile heat accumulator possesses a weight of about 5000 g/m 2 and a thickness of about 8 millimetres. The latent heat storage capacity of the textile heat accumulator totals about 1000 kJ/m 2 .
[0026] The textile heat accumulator is used in roofs of residential and commercial buildings. FIG. 2 shows a sectional view of a common roof structure where the textile heat accumulator is arranged in its upper part. The preferable arrangement of the textile heat accumulator ( 7 ) in a roof of a building is below the roof tiles ( 5 ) mounted on the wooden boarding ( 6 ) and above the thermal insulation package consisting of the underlay ( 8 ), the thermal insulation layer ( 9 ) and the water vapor barrier ( 10 ) as well as the dry wall ( 11 ). In this arrangement, it can be expected that the temperature of the phase change material and the surrounding elastomeric compound will increase to values during the day at which the latent heat absorption takes place. The space between the textile heat accumulator and the insulation package ensures an air and moisture transfer required for such roof constructions.
[0027] It has been discovered that the incorporation of temperature stabilizing phase change material in roof structures of buildings can improve the thermal performance of residential and commercial buildings significantly. In the invented technique, the phase change material shall provide a thermal control mechanism of the heat flux into the building through the roof components. For instance, the phase change material shall absorb part of the heat provided by the solar radiation during the day. The heat absorption by the phase change material reduces the heat flux into the building. Especially on hot summer days, the thermal comfort inside the building will be enhanced significantly as a result of the phase change material's heat absorption feature. As a result of the thermal control mechanism provided by the phase change material, air-conditioning demands of the facility will be reduced and, therefore, the building becomes more energy efficient.
[0028] However, in addition to the described thermal effect the latent heat stored in the phase change material can be used to generate hot water in a way which is similar to those of a solar hot water system. Under these circumstances, the phase change material will be recharged during the day instead of overnight which makes the heat absorption feature of the phase change material even more efficient. As a result of the recharge, the latent heat absorption process of the phase change material will occur more than once during the day.
[0029] Starting in the morning, the phase change material integrated in the textile heat accumulator will absorb latent heat as soon as the materials temperature exceeds a certain value. During the latent heat absorption, the phase change material's temperature will stay nearly constant. When all of the phase change material is melted, its temperature will rise further. A temperature sensor ( 14 ) integrated in the textile heat accumulator ( 7 ) unit shown in FIG. 3 will measure the temperature development. The temperature measurement delivers an indication at which point the phase change material is ready for a recharge., i.e. when the temperature exceeds a certain value, the sensor provides a signal to the valve ( 13 ) which normally shuts off the cold water supply. The valve opens and cold water with a temperature of about 15° C. is transported though pipes by means of the pump ( 12 ) and further through the capillary pipes ( 2 ) which are integrated into the textile heat accumulator. Because of the high temperature gradient between the phase change material's temperature of about 65° C. and the water temperature of about 15° C. at the beginning, there is a fast transfer of the latent heat stored in the phase change material to the water and the water is heated. The water which flows out of the textile heat accumulator possess a temperature of about 45° C. The hot water can be used immediately or stored in a small tank ( 15 ) to be used at a later time. Beside the possibility of an automated recharge of the phase change material if the temperature exceeds a given value, there is also the opportunity to store the latent heat over such a period of time until a hot water supply is actually required. That way, the cold water valve needs to be opened manually.
[0030] For instance, the latent heat storage capacity of 1000 kJ stored in a textile heat accumulator with a size of 1 m 2 is sufficient to heat up about 8 liters of water from 15° C. to 45° C. in one recharge. A total textile heat accumulator size of 6 m 2 already delivers the daily water supply demand for one person in a single recharge. It has to be considered that there are multiple recharges possible during the day.
[0031] A common solar hot water system consists of a solar collector and a large storage tank with a heat exchanger attached to it. A heat transfer fluid is pumped through the solar collector where it is heated. The heat transport fluid is further pumped into the storage tank and through the heat exchanger where the cold water on the bottom of the tank is heated up. The warmer water then rises to the top of the storage tank.
[0032] In comparison to the common solar hot water system, the textile heat accumulator system does not require a large storage tank with a heat exchanger. The heat exchange takes place in the textile heat accumulator itself and the recharge can be carried out several times during the day. The omission of storage tank, heat exchanger and heat exchange fluid leads to substantial savings in costs and space. In addition, the textile heat accumulator is essential cheaper than the solar collector of a common solar hot water system. The textile heat accumulator is comparatively light, thin and flexible.
[0033] In addition to roofs of residential and commercial buildings, the textile heat accumulator is also suitable for an application in the roof of a greenhouse. Furthermore, the textile heat accumulator can be applied to a membrane roof construction.
[0034] Preferred embodiments of the present invention have been described with a degree of particularity. It should be understood that this description has been made by way of preferred example, and that the invention is defined by the scope of the claims.
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The invention relates to a textile heat accumulator consisting of a textile carrier material to which a plurality of thin capillaries for water transportation are attached and which is coated with an elastomeric compound comprising finely divided phase change materials such as salt hydrates or crystalline alkyl hydrocarbons. The textile heat accumulator arranged in a roofing structure of a building facilitates the control of the heat flux into the building and the utilization of the latent heat stored within phase change material for hot water generation.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a filtering device for eliminating unsolicited email, and particularly relates to a filtering device that is not only able to eliminate unsolicited email, but also provides interfaces, through which the users can actively adjust some function of the device when in practice.
[0003] 2. Description of Related Art
[0004] Emailing has revolutionized written communications but nearly all the internet users suffer from unsolicited, undesired, nuisance emails. This is an extremely irritating situation as not only is the mail offensive in its failure to respect peoples' privacy, it can often jam an email box because of the large size of the mails and so a user then cannot receive desired, genuine emails. The email senders can easily send a lot of emails by some email-sending software, while the email receivers have to spend a large amount of time dealing with these emails. Although some email filtering devices are popular in the market, the junk email senders can always find the backdoors of the filtering device, so that the email preventing function becomes ineffective.
[0005] Therefore, the invention provides a filtering device which eliminates unsolicited, nuisance email to mitigate or obviate the aforementioned problems.
SUMMARY OF THE INVENTION
[0006] The main objective of the present invention is to provide a multi-functional filtering device to eliminate unsolicited junk emails. The junk emails are classified into several groups based on their respective styles and a comparing database is built up to increase the email elimination efficiency.
[0007] Other objectives, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a block system diagram in accordance with this invention;
[0009] FIG. 2 is a block diagram of a filtering engine in accordance with this invention;
[0010] FIG. 3 is a block diagram of a conditional content comparing module in the filtering engine in accordance with this invention; and
[0011] FIG. 4 is a block diagram of a keyword-based comparing unit in the conditional content comparing module in accordance with this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0012] FIG. 1 shows a block system diagram of this invention composed of a filtering engine ( 10 ) to eliminate the unsolicited emails in received emails, thus the unsolicited emails are denied entry while genuine, desired mails are unimpeded. An email intercept display ( 20 ) is responsible for the arrangement of the rejected emails, and sends the accumulated such emails to the receiver every certain time to facilitate the checking of the emails by the receiver. Of course, the receiver can also enter the intercept email display ( 20 ) to skim through the rejected emails to actively commit the management of the emails. A statistic engine ( 30 ) is applied to provide data charts to be analyzed by the receiver. A white-list filtering engine ( 40 ) is used for permitting entry by some genuinely important emails.
[0013] As shown in FIG. 2 , the filtering engine ( 10 ) has an online mode filtering module ( 11 ) for checking the abnormal online connection. Any abnormal connection will be automatically recorded in the black-list. In this embodiment, the online mode filtering module ( 11 ) consists of a DoS defensive filter. A general DoS defensive filter can prevent an instant email flood based on the bottom layer communication protocol via a network adapter card or predetermine a black-list to directly refuse the email flood. In this invention, the DoS defensive filter will connect to the Port 25 at the moment of filtering, and once the accumulated emails in a certain time period exceeds a reasonable amount, the defensive filter will be activated and add the related addresses to the black-list. In addition, the black-list can be set as being invalid or permanently valid or fully automatic.
[0014] A black-list filtering module ( 12 ) is mainly used to recognize the sender, IP and Domain of the unsolicited emails and refuse them directly without further judgment. To avoid rejecting useful emails by mistake, a white-list is also built to record the trusted partners' emails, which can pass without any judgment.
[0015] A specified content comparing module ( 13 ) is responsible for distinguishing emails with specified letters or words, which can more effectively prevent the unwanted emails and facilitate centralized management of some specified letters.
[0016] A conditional content comparing module ( 14 ) is used to conclude most unsolicited email styles based on experience of previous such emails, further cooperating with weighting operation to increase the veracity of email judgment, meanwhile, a comparing database is built up.
[0017] An automatic learning module ( 15 ) is responsible for accepting the sample emails and learning their characteristics, and then it proceeds with intelligent management of emails. If there are many sample undesired emails received therein, the automatic learning module ( 15 ) will remember the characteristics of those emails as a base for subsequent filtering exercises.
[0018] The conditional content comparing module ( 14 ) is further composed of a keyword-based comparing unit ( 141 ) which can filter some kinds of emails based on most keywords in previous emails, but the email only has pictures or hyperlinks which can not be recognized by the keyword-based comparing unit ( 14 ). A feature comparing filtering unit ( 142 ) cooperates with the keyword-based comparing unit ( 141 ) which can recognize the unrequited emails only having pictures or hyperlinks. A keyword classification management unit ( 143 ) can classify the keywords into different groups to meet the requirement of each section in the company.
[0019] The keyword-based comparing unit ( 141 ) consists of a common keyword-based group database and a private keyword-based group database. In the former database, the Chinese sample undesired emails are classified into different groups to abstract the keywords of different groups, each keyword being distributed a value; a weighting value will be added to a sum of these values to obtain a threshold value. Once the accumulated value of keywords passes the threshold value, the corresponding email will be marked as undesired email and thrown into an email bin. The frequency and value of each keyword can be seen in the email bin. The latter database adapted to the users' requirement can define a private keyword database. When a new type of unsolicited email is developed and which can not be checked by the common keyword-based group database, the user can send this email to an “email callback” with an individual definition.
[0020] In addition, the feature comparing filtering unit ( 142 ) provides a special weighting value to enhance the filtering function. In the special weighting value, the following filtering rules are added:
1. A sender shown in the email is not the real sender based on SMTP (simple mail transfer protocol) protocol. A deceitful email sender may forge a sender ID to trick the recipient. 2. A receiver shown in the email is not the user. A junk email sender may forge a receiver to cause curiosity, ie an actual receiver may believe an incorrect address was used and be sufficiently intrigued to open the mail. 3. A receiver in the email is not disclosed. The email with unidentified receiver is filtered. 4. Weighting value of the keyword in the major part is multiplied. Some undesired emails have only a few letters or even no letters, but the email keywords are obvious in the major part, thus the weighting value will be multiplied. 5. The major part is 8 characters between English letters. Some emails are covered up by that way to avoid keyword-based filtering. 6. Plain picture links. Some emails have a lot of plain picture links to avoid keyword-based filtering. 7. Abnormal HTML (Hypertext Markup Language) recognition. A lot of undesired emails adopt the HTML volume labels to emphasize their product advertisement. HTML TAG operation is adopted in this invention.
[0028] Whether each of the above rules is to be activated can be determined by the users, and the value of each rule is also predetermined by the users. The special value will be together with keyword-based comparing method to be recognized by conditional content comparing method. Each rejected email will be distributed to a corresponding group; if the junk email has only a plain picture or hyperlinks that can not be detected by the keyword-based method, as long as an accumulated value of the special weighting exceeds that of other type of advertisement email, the special weighting email will be rejected and marked as a kind of advertisement email.
[0029] Generally, the unsolicited emails will be thrown away or put in a certain place, and then the user will decide how to deal with such emails. However, some vital email may be inevitably classified as undesired email. Filtered by specified content comparing module ( 13 ) and conditional content comparing module ( 14 ), all the unsolicited emails are recorded and displayed by the email intercept display ( 20 ). The caught email will be deposited safely in the host computer.
[0030] In addition to the email manager, the rejected emails can be classified into different groups, which are open to different users respectively, thus the user can check the rejected emails based on their respective requirement. Such kind of function not only considers individualization, but also shares the tasks of the email manager.
[0031] The statistic engine ( 30 ) provides a statistical chart automatically drawn thereby, which facilitates the checking of an email flow capacity, an unsolicited email flow capacity, re-post email statistics, email source statistics and DoS online attack times statistics.
[0032] The above statistic engine ( 30 ) can be activated every day, every week, every month or at a certain period set by the user, moreover, the statistic result can be reordered based on the requirement.
[0033] As the user may have a certain type of important emails, the white-list filtering engine ( 40 ) will let such kind of emails get through according to a predetermined parameter. In this way, the important email will not be filtered by mistake.
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A filtering device for determining and disposing of unsolicited emails is mounted at a front end of a mail server of a company. A filtering engine will compare and filter all the received emails. The filtering engine has an online mode filtering module, a black-list filtering module, a specified content comparing module and a conditional content comparing module, all of which are cooperating together to increase the veracity of email judgment.
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BACKGROUND OF THE INVENTION
[0001] Bird feeders are often equipped with a variety of different components to accommodate different needs, uses, and desires. For instance, feeders routinely have perches on which birds stand during feeding, but sometimes additional perches for larger birds are required or wanted. Certain feeders have squirrel and other small animal guards for situations in which it is necessary to prevent intrusion by these animals. There is, however, currently no bird feeder which is readily adaptable to permit bird feeder components to be interchangeable, i.e. to be added or removed from the feeder, depending on user desire or specific need.
[0002] Additionally, pole mounted bird feeders are usually positioned at a height which makes it difficult for the normal sized individual to refill the feeder. Step stools or small ladders are often used to awkwardly fill empty feeders, presenting a bother, if not a real danger to the user. Ease of filling feeders without loss of bird food being poured into the feeder's storage compartment is also a problem which is encountered when attempting to replenish a feeder.
SUMMARY OF THE INVENTION
[0003] It is thus the object of the present invention to address and solve the disadvantages and limitations of prior bird feeders.
[0004] It is an object of the present invention to provide a modular bird feeder system which has a plurality of compatible, but different, interchangeable, modular bird feeder components.
[0005] It is another object of the present invention to provide a modular bird feeder system which has a plurality of modular bird feeder components which can be readily connected and disconnected, according to the needs and desires of the user.
[0006] It is a further object of the present invention to provide a modular bird feeder system which allows the interchangeable use of several, all, or none of its available modular bird feeder components, by providing for quick and effective connections between components.
[0007] It is still another object of the present invention to provide a modular bird feeder system which is easily and safely filled with bird food.
[0008] It is an object of the present invention to provide a modular bird feeder system which allows the height of the bird feeder itself to be adjusted, for convenient and safe filling of the bird feeder unit itself.
[0009] It is still a further object of the present invention to provide a modular bird feeder system which provides an efficient and wasteless bird feed filling component which is integral with the system.
[0010] These and other objects are accomplished by the present invention, a modular bird feeder system which comprises a plurality of different modular bird feeder components which can be interchangeably connected based on user preference or need. All components are slideably mounted on a vertically standing pole. The slideable components include a feed filling funnel, an upper feed tray, a lower feed tray, a squirrel guard, and a feeder unit position adjustment handgrip which controls the upward and downward movement along the pole of the integral bird feeder unit which is assembled. An adjustable locking pin extending from the pole is used to maintain the bird feeder unit in the uppermost bird feeding position on the pole, regardless of which components are being used. When the pin is removed, the handgrip facilitates control of the bird feeder unit as it slides from its bird feeding position to a user-friendly, convenient feed filling position on the pole.
[0011] The novel features which are considered as characteristic of the invention are set forth in particular in the appended claims. The invention, itself, however, both as to its design, construction and use, together with additional features and advantages thereof, are best understood upon review of the following detailed description with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is an exploded cross-section view of the basic upper components of the bird feeder system of the present invention.
[0013] FIG. 2 is a cross-section view of the lower feed tray of the present invention.
[0014] FIG. 3 is a cross-section view of the squirrel guard of the present invention.
[0015] FIG. 4 is a cross-section view of the control handgrip of the present invention.
[0016] FIG. 5 is a cross-section view of the basic bird feeder unit configuration of the present invention.
[0017] FIG. 6 is a cross-section view of an alternate bird feeder unit configuration of the present invention.
[0018] FIG. 7 is a cross-section view of still another bird feeder unit configuration of the present invention.
[0019] FIG. 8 is a cross-section view of a further bird feeder unit configuration of the present invention.
[0020] FIG. 9 is a view of the bird feeder system of the present invention in the bird feeding position.
[0021] FIG. 10 is a view of the bird feeder system of the present invention in the feed filling position.
[0022] FIG. 11 is a view of the locking pin configuration of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The bird feeder system of the present invention comprises a number of separable, modular components which are configured to be conveniently assembled to form various integral bird feeder unit configurations 1 a ( FIG. 5 ), 1 b ( FIG. 6 ), 1 c ( FIG. 7 ), and 1 d ( FIG. 8 ). Roof 2 , comprising pole guide compartment 3 , is removeably positioned on filling funnel 4 , which itself is designed to mate with feed housing tube 6 . As best seen in FIG. 5 , ring 5 is attached to and extends completely around the underside of roof 2 . Roof 2 is configured to be positioned on filling funnel 4 , inboard of ring 5 , in order to prevent the ingress of weather elements, such as water and wind, into the filling funnel and hence into feed housing tube 6 . It is contemplated that housing feed tube 6 will be constructed of plastic or similar material, and, if of clear material, to permit visual observation of bird feed levels. Feed housing tube 6 is shown as being cylindrical in shape, with open space 8 . However, the shape and configuration of this component as well as roof 2 is not to be considered restricted to that which is disclosed. Any convenient or desired shaped feed housing container or roof can be used.
[0024] Housing feed tube 6 is in turn placed on upper feed tray 10 . Feed tray 10 comprises center tube support 12 with through channel 13 . Upper section 14 of center tube support 12 is configured to extend into feed housing tube 6 , the lower section 16 having threaded connection 18 . Small bird feeding platform 19 extends from tube support 12 . Threaded connection 18 of upper feed tray 10 is configured to be threadably mated with any of the threaded connections of the other module components of the invention: lower feed tray 20 , squirrel guard 30 , and feeder position control handgrip 40 .
[0025] Lower feed tray 20 comprises center tube support 22 with through channel 23 , upper threaded connection 24 and lower threaded connection 26 . Large bird feeding platform 28 extends from tube support 22 .
[0026] Squirrel guard 30 comprises concave, curvilinear protective shell 32 , which has open bottom 35 . Center tube support 34 has through channel 33 , upper thread connection 36 , and lower thread connection 38 .
[0027] Feeder unit position adjustment control handgrip 40 comprises elongated tube 42 open at each end and sized for grasping by a user. Channel 43 extends through handgrip 40 . Threaded connection 46 is located at the upper end of handgrip 40 and flared base section 48 is located at the lower end.
[0028] Elongated mounting pole 50 is configured to be vertically standing, secured within a ground foundation, as is common in the art. Pole 50 is designed to extend through channel 43 of handgrip 40 , channel 33 of center tube 34 of squirrel guard 30 , channel 23 of center tube 22 of lower feed tray 20 , channel 13 of center tube support 12 of upper feed tray 10 , housing feed tube 6 , and feed filling funnel 4 . Roof 2 rests on upper end 52 of pole 50 , the upper end being positioned within pole guide compartment 3 extending down from the roof. Locking pin 54 is configured to extend through pole 50 , to maintain the bird feeder 1 on the pole in its uppermost bird feeding position, as is described hereinafter.
[0029] An integral bird feeder unit of the bird feeder is formed by the assembly of different modular components. For instance, FIG. 5 shows basic, integral bird feeder unit 1 a , with roof 2 , filling funnel 4 , housing feed tube 6 , upper feed tray 10 , and central handgrip 40 , connected and fully assembled around pole 50 . FIG. 9 shows this particular bird feeder unit mounted in its uppermost, bird feeding position on pole 50 . Bird feed 60 fills housing feed tube 6 . In this configuration, threaded connection 46 of handgrip 40 is threadably mated with threaded connection 18 of upper feed tray 10 , as shown in FIG. 5 . Bird feeder unit is maintained in this uppermost position on the pole by locking pin 54 through pole 50 .
[0030] Locking pin 54 comprises finger section 56 which interconnects elongated arm section 58 with pole cradle section 60 . There is resiliency between sections 58 and 60 which permits these sections to spread apart when a force is applied between them. Elongated arm section 58 is configured to be inserted through holes located through pole 50 . FIG. 9 shows holes 62 , 64 , 66 , and 68 on one side of pole 50 . Another set of four holes corresponding to these holes, and immediately across from them, is located on the other side of pole 50 . See also FIG. 11 , showing hole 64 and opposite, corresponding hole 65 .
[0031] Once the assembled bird feed unit, for instance the unit shown in FIG. 9 , is slideably raised up to its desired height by means of position adjustment control handgrip 40 , locking pin 54 is inserted into hole 62 and opposite, corresponding hole. As locking pin 54 is being so inserted, arm section 58 and pole cradle section 60 are pushed against the surface of pole 50 , as the pole is forced between these sections. The resiliency between arm section 58 and pole cradle section 60 causes the two sections to spread apart to accept and then close to maintain pole 50 between the sections. Once locking pin 54 is fully inserted into hole 62 and its opposite hole, the locking pin is secured within the pole. Base 48 of control handgrip 40 can then rest atop locking pin 54 and the bird feeder unit is maintained in this uppermost position on the pole.
[0032] When it is necessary to fill the bird feeder unit with feed, finger section 56 makes it easy to remove locking pin 54 from pole 50 . This allows all components of the bird feeder unit, except roof 2 which remains positioned on pole 50 , to slide down the pole, until control handgrip 40 reaches fixed stop support 70 , secured around the pole. See FIG. 10 . Base 48 of control handgrip 48 then rests on stop support 70 to maintain the bird feeder unit in this position on pole 50 . Stop support 70 can be a circular washer permanently attached around pole 50 , or equivalent stop component, large enough to support base 48 of control handgrip 40 . Stop support 70 is located on pole 50 at a height which allows comfortable filling of the bird feeder unit such that, in this position, feed can easily be added to housing feed tube 6 , via filling funnel 4 . It is contemplated that this position will place filling funnel 4 at a height adjacent to the waist of an individual of average height.
[0033] When the feed filling operation is completed, the bird feeder unit is simply slid up pole 50 to the uppermost position on the pole. Locking pin 54 is then inserted into the holes in the pole which maintain the bird feeder unit at this desired height.
[0034] Another significant novel advantage of the bird feeder system of the invention is that it allows the ability to add and mix and match different modular components, depending on user preference. While bird feeder unit la can be used solely with upper feed tray 10 , as shown in FIG. 5 , the bird feeder unit can also comprise lower feed tray 20 and/or squirrel guard 30 , each easily and interchangeably added.
[0035] For example, FIG. 6 shows bird feeder unit 1 b , with the inclusion of lower feed tray 20 connected at its upper threaded connection 24 to threaded connection 18 of upper feed tray 10 and at its lower threaded connection 26 to threaded connection 46 of handgrip 40 . FIG. 7 shows bird feeder unit 1 c , with squirrel guard 30 connected at its upper threaded connection 36 to threaded connection 18 of upper feed tray 10 , and its lower threaded connection 38 connected to threaded connection 46 of handgrip 40 . FIG. 8 shows bird feeder unit id with all available modular components in use, upper feed tray 10 being connected at threaded connection 18 to lower feed tray 20 at its connection 24 , the lower feed tray being connected at its threaded connection 26 to squirrel guard 30 at its connection 36 , and the squirrel guard in turn connected at its connection 38 to handgrip 40 at its connection 46 .
[0036] Adding components to the assembled bird feeder unit increases the length of the overall unit. This added length of the bird feeder unit on pole 50 is accommodated by adjusting the position of locking pin 54 through the pole. When configured as in FIG. 6 , bird feeder unit 1 b is maintained in position on pole 50 by locking pin 54 through hole 64 and its corresponding opposite hole 65 . When configured as in FIG. 7 , bird feeder unit 1 c is maintained in position on pole 50 by locking pin 54 through hole 66 and its corresponding opposite hole. And when configured as in FIG. 8 , bird feeder unit 1 d is maintained in position on pole 50 by locking pin 54 through hole 68 and its corresponding opposite hole.
[0037] Of course, since all the modular components are slideably mounted around pole 50 , regardless of the configuration of the bird feeder unit and placement of the components, the height of the unit on the pole can be easily and simply adjusted for filling by the slideably movement of handgrip 40 over the pole onto stop support 70 .
[0038] Thus, by this invention, a versatile bird feeder system is provided which allows the flexibility to interchange feeder components and, regardless of its configuration, provides a means to easily refill the feeder without the use of ladders or step stools or removing the feeder from its mounting.
[0039] Certain novel features and components of this invention are disclosed in detail in order to make the invention clear in at least one form thereof. However, it is to be clearly understood that the invention as disclosed is not necessarily limited to the exact form and details as disclosed, since it is apparent that various modifications and changes may be made without departing from the spirit of the invention.
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A modular bird feeder system has a plurality of different modular bird feeder components which can be interchangeably connected based on user preference. All components are slideably mounted on a vertically standing pole. The slideable components include a feed filling funnel, an upper feed tray, a lower feed tray, a squirrel guard, and a feeder unit position adjustment handgrip which controls the upward and downward movement along the pole of the integral bird feeder unit which is assembled. An adjustable locking pin extending from the pole is used to maintain the bird feeder unit in the uppermost bird feeding position on the pole, regardless of which components are being used. When the pin is removed, the handgrip facilitates control of the bird feeder unit as it slides from its bird feeding position to a user-friendly, convenient feed filling position on the pole.
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BACKGROUND
[0001] 1. Technical Field
[0002] The disclosure generally relates to power test apparatuses, and particularly to a power test apparatus for a power supply.
[0003] 2. Description of the Related Art
[0004] Many electronic devices, such as servers, employ a motherboard and a power supply providing power for the motherboard. In order to test power range of the power supply, the power supply must be electronically connected to different loads (e.g., a motherboard). Thus, operators can immediately know the power range of the power supply. However, it may be inconvenient for the operators to have to connect/disconnect the power supply to/from the different loads.
[0005] Therefore, there is room for improvement within the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Many aspects of the present disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the present embodiments.
[0007] FIG. 1 is a block diagram of a power test device for a power supply, according to an exemplary embodiment.
[0008] FIG. 2 is a circuit view of the power test device as shown in FIG. 1 .
DETAILED DESCRIPTION
[0009] FIG. 1 shows an exemplary embodiment of a power test device 100 . The power test device 100 is configured to test a power range of a power supply 200 .
[0010] The power test device 100 includes a main board 10 and a load circuit 30 integrated on the main board 10 . The main board 10 can be a motherboard of an electronic device (not shown), such as a server.
[0011] The main board 10 includes a port 12 and a power button 14 . The main board 10 is electronically connected to the power supply 200 via the port 12 . When the power button 14 is actuated, the main board 10 is activated. The main board 10 receives power from the power supply 200 , and provides a standby voltage source 5VSB, a first driving voltage source 5V, and a second driving voltage source 12V to the load circuit 30 . Specifically, the standby voltage source 5VSB is generated as long as the main board 10 is electronically connected to the power supply 200 , the first driving voltage source 5V and the second driving voltage source 12V are generated when the button 14 is actuated.
[0012] FIG. 2 shows that in one exemplary embodiment, the load circuit 30 includes a first switch SW 1 , a second switch SW 2 , five control circuits 31 , 32 , 33 , 34 , and 35 , and five load resistors R 1 , R 2 , R 3 , R 4 , and R 5 . A total power consumption of the load circuit 30 can be changed through activating a different number of the five load resistors R 1 , R 2 , R 3 , R 4 , and R 5 .
[0013] In one exemplary embodiment, the first switch SW 1 activates the control circuits 31 , 32 , and 33 . The first switch SW 1 is a toggle switch, and includes a first terminal S 1 , a second terminal S 2 , a third terminal S 3 , a fourth terminal S 4 , a fifth terminal S 5 , and a sixth terminal S 6 . The first switch SW 1 further includes three switch toggles 301 (or levers, buttons, etc). The first terminal S 1 can be electronically connected to/disconnected from the sixth terminal S 6 by manipulation of one of the three switch toggles 301 . The second terminal S 2 can be electronically connected to/disconnected from the fifth terminal S 5 by manipulation of one of the three switch toggles 301 . The third terminal S 3 can be electronically connected to/disconnected from the fourth terminal S 4 by manipulation of one of the three switch toggles 301 . The first terminal S 1 , the second terminal S 2 , and the third terminal S 3 are all electronically connected to the first driving voltage source 5V, the fourth terminal S 4 , the fifth terminal S 5 , and the sixth terminal S 6 are electronically connected to the control circuits 31 , 32 , and 33 , respectively.
[0014] In one exemplary embodiment, the second switch SW 2 activates the control circuits 34 and 35 . The second switch SW 2 is a toggle switch, and includes a first terminal S 1 , a second terminal S 2 , a third terminal S 3 , and a fourth terminal S 4 . The first switch SW 1 further includes two switch toggles 302 such as levers or buttons, for example. The first terminal S 1 can be electronically connected to/disconnected from the fourth terminal S 4 by manipulation of one of the two switch toggles 302 . The second terminal S 2 can be electronically connected to/disconnected from the third terminal S 3 by manipulation of one of the two switch toggles 302 . Both the first terminal S 1 and the second terminal S 2 are electronically connected to the first driving voltage source 5V, the third terminal S 3 and the fourth terminal S 4 are electronically connected to the control circuits 34 , and 35 , respectively.
[0015] Each of the five control circuits 31 , 32 , 33 , 34 , and 35 includes a metallic oxide semiconductor field effect transistor (MOSFET) Q and a bias resistor R. The MOSFET Q is in a form of an 8-pin microchip, and is used to stabilize output voltages. The MOSFET Q includes a gate G, a source S, and drains D 1 , D 2 , and D 3 . The gate G is electronically connected to ground via the bias resistor R, the source S is electronically connected to ground, and the drains D 1 , D 2 , and D 3 are electronically interconnected to form a node A.
[0016] Additionally, the gate G of the MOSFET Q of the control circuit 31 is electronically connected the sixth terminal S 6 of the first switch SW 1 . The gate G of the MOSFET Q of the control circuit 32 is electronically connected the fifth terminal S 5 of the first switch SW 1 . The gate G of the MOSFET Q of the control circuit 33 is electronically connected the fourth terminal S 4 of the first switch SW 1 . The gate G of the MOSFET Q of the control circuit 34 is electronically connected the fourth terminal S 4 of the second switch SW 2 . The gate G of the MOSFET Q of the control circuit 35 is electronically connected the third terminal S 3 of the second switch SW 2 .
[0017] The load resistor R 1 is electronically connected between the standby voltage source 5VSB and the node A of the control circuit 31 . The load resistor R 2 is electronically connected between the second driving voltage source 12V and the node A of the control circuit 32 . The load resistor R 3 is electronically connected between the second driving voltage source 12V and the node A of the control circuit 33 . The load resistor R 4 is electronically connected between the second driving voltage source 12V and the node A of the control circuit 34 . The load resistor R 5 is electronically connected between the second driving voltage source 12V and the node A of the control circuit 35 . In one exemplary embodiment, rated power consumptions of the load resistors R 1 , R 2 , R 3 , R 4 , and R 5 are all about 50 watts.
[0018] When the power range of the power supply 200 is tested, the power supply 200 is electronically connected to the main board 10 via the port 12 . Thus, the main board 10 supplies the standby voltage source 5VSB to the load circuit 30 . When the power button 14 is actuated, the main board 10 supplies the first driving voltage source 5V and the second driving voltage source 12V to the load circuit 30 .
[0019] If a rated power of the power supply 200 is about 160 watts, then operators manipulate the switch toggles 301 of the first switch SW 1 to allow the first terminal S 1 to be electronically connected to the sixth terminal S 6 , the second terminal S 2 to be electronically connected to the fifth terminal S 5 , the third terminal S 3 to be electronically connected to the fourth terminal S 4 . Thus, the gates G of the control circuits 31 , 32 , and 33 receive a high voltage (e.g., 5V) from the first driving voltage source 5V. Then, the MOSFET Q of the control circuits 31 , 32 , and 33 are turned on, and the load resistors R 1 , R 2 , and R 3 are activated. The total power consumption of the load resistors R 1 , R 2 , and R 3 is about 150 watts. In the above example, if the power supply works normally, the maximum power of the power supply 200 may reach 150 watts, and is approaching to the rated power of the power supply 200 . If the power supply works abnormally (e.g., turn off), the maximum power of the power supply 200 may not reach 150 watts.
[0020] If a rated power of the power supply 200 is about 120 watts, then operators manipulate the switch toggles 302 of the second switch SW 2 to allow the first terminal S 2 to be electronically connected to the fourth terminal S 4 , the second terminal S 2 to be electronically connected to the third terminal S 3 . Thus, the gates G of the control circuits 34 , and 35 receive a high voltage (e.g., 5V) from the first driving voltage source 5V. Then, the MOSFETs Q of the control circuits 31 , and 35 are turned on, and the load resistors R 4 , and R 5 are activated. The total power consumption of the load resistors R 4 , and R 5 is about 100 watts. In the above example, if the power supply works normally, the maximum power of the power supply 200 may reach 100 watts, and is approaching to the rated power of the power supply 200 . If the power supply works abnormally (e.g., turn off), the maximum power of the power supply 200 may not reach 100 watts.
[0021] In other embodiments, one of the first switch SW 1 and the second switch SW 2 can be omitted. For example, if the second switch SW 2 is omitted, the power test device 100 can test the rated power of the power supply 200 of about 50-150 watts through the first switch SW 1 , the control circuits 31 , 32 , and 33 , and load resistors R 1 , R 2 , and R 3 .
[0022] In other embodiments, the rated power consumptions of the load resistors R 1 , R 2 , R 3 , R 4 , and R 5 can be different, for example, the rated power consumptions of the load resistors R 1 , R 2 , and R 3 are all about 45 watts, and the rated power consumptions of the load resistors R 4 , and R 5 are both about 30 watts.
[0023] In summary, the operators can manipulate the first switch SW 1 and the second SW 2 to turn on the at least one of the control circuits 31 , 32 , 33 , 34 , and 35 , and then the corresponding load resistors R 1 , R 2 , R 3 , R 4 , and R 5 are activated and are served as the load of the power supply 200 . Thus, the power test device 100 can test the power range of the power supply 200 . Additionally, the power supply 200 does not need to physically and repeatedly be connected to/disconnected from different loads. Therefore, the power test device 100 is both efficient and convenient.
[0024] Although numerous characteristics and advantages of the exemplary embodiments have been set forth in the foregoing description, together with details of the structures and functions of the exemplary embodiments, the disclosure is illustrative only, and changes may be made in detail, especially in the matters of arrangement of parts within the principles of disclosure to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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A power test board for a power supply includes a main board and a load circuit. The load circuit includes at least one switch, at least one control circuit, and at least one load resistor. A number of the load resistor being same with a number of the control circuit, each load resistor is electronically connected to one of the at least one control circuit. Toggling of the at least one switch to electronically connect to the control circuit causes the control circuit to be electronically connected to the power supply, the at least one control circuit is turned on, and the at least one load resistor is activated to serve as a load of the power supply.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a Continuation-in-Part of U.S. patent application Ser. No. 09/779,238 filed on Feb. 8, 2001.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to a measuring device and relates in particular to a device for measuring deployment and operating forces on a well logging instrument.
[0004] 2. Description of the Related Art
[0005] In the deployment of well logging instruments and devices in wells, it is desired to remotely monitor and quantify the forces applied to the instrument string by the various deployment means such as wire line/armored cable with or without assistance of well tractor, caterpillar, worm, crawler, mule, or other push/pull devices; pipe conveyed; or coiled tubing conveyed. A downhole force gage is used for sensing and monitoring the forces applied to the instrument string.
[0006] Existing downhole force gages, also called cable head tension sensors, typically employ strain gage sensors to monitor the mechanical strains induced by deployment forces. The strain gages are mounted on a high strength body which is housed in a sealed internal cavity of the gage assembly. The strain gages are attached and bonded with adhesive or other techniques to the strain gage body and configured electrically as a balanced bridge circuit. Mechanical strain proportional to the applied tension or compression load is induced into the strain gage body. With the bridge circuit powered by a constant, regulated d.c. voltage (typically 10 volts), the strain gage bridge outputs a signal (typically in millivolts) proportional to the applied loads.
[0007] When submerged in a fluid filled borehole, hydrostatic pressure impinges on the downhole instrument string and force gage assembly, and produces an external differential pressure force which acts upon the force gage assembly. These hydrostatic pressure forces induce undesired proportional offsets in the strain gage output, so a pressure equalizing system is utilized to eliminate the effects of hydrostatic pressure.
[0008] A typical force gage assembly is configured with a suitable floating piston (or an elastic bellows), and the internal cavity of the assembly is filled with a suitable hydraulic fluid. The floating piston (or elastic bellows) moves to accommodate any changes in the volume of the hydraulic fluid in the internal cavity due to changes in hydrostatic pressure or due to changes in temperature. By this means the internal cavity of the force gage assembly is thus pressure-equalized to external hydrostatic pressure, and also by this means the internal cavity, together with the strain gage bridge circuits and wiring, are protected from direct contact with the borehole fluids.
[0009] However, the typical configuration is complex, has relatively high cost of manufacture, has relatively high cost of maintenance, and requires hydraulic fluid filling of the force gage assembly. The strain gages are in contact with hydraulic fluid which can be a path of electrical leakage, and over time the hydraulic fluid can attack and degrade the strain gage adhesive bonds. The strain gages also are exposed to hydrostatic pressure which induces some inaccuracy in the output signal. Therefore, there is a demonstrated need for a force gage that eliminates the effects of downhole pressure while maintaining the sensing elements in a gas filled chamber.
SUMMARY OF THE INVENTION
[0010] The present invention addresses the above-noted and other deficiencies in the prior art and provides a downhole force gage for measuring both compression and tension forces on a well logging instrument string.
[0011] This invention provides more accurate load measurement by isolating the strain sensing elements from all effects of downhole pressure. The sensing elements are disposed on a load rod and are located in an atmospheric pressure housing. The strain sensing load rod is pressure balanced by suitable selection of multiple seal diameters such that the external pressure loads on the load rod are canceled out essentially eliminating the effects of downhole pressure on the load measurement.
[0012] In one aspect of the invention, strain gages are adhesively bonded to the sensing member to form a conventional bridge circuit.
[0013] In another embodiment, strain gages are vacuum deposited on the sensing member.
[0014] Examples of the more important features of the invention thus have been summarized rather broadly in order that the detailed description thereof that follows maybe better understood, and in order that the contributions to the art may be appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject of the claims appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] For detailed understanding of the present invention, references should be made to the following detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings, in which like elements have been given like numerals, wherein:
[0016] [0016]FIG. 1 show a schematic diagram of a well logging instrument being deployed in a wellbore.
[0017] [0017]FIG. 2 shows a schematic diagram of a load measuring tool according to one embodiment of the present invention.
[0018] [0018]FIG. 3 shows a schematic diagram of a load rod according to one embodiment of the present invention.
[0019] [0019]FIG. 4 show a schematic diagram of a seal body according to one embodiment of the present invention.
[0020] [0020]FIG. 5 show a schematic diagram of the forces imposed on the load rod according to one embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] [0021]FIG. 1 is a schematic showing of a well logging instrument string 45 suspended in a borehole 65 at the end of a braided wireline 70 . The braided wireline 70 runs over pulleys (not shown) at the surface and winds on a surface winch (not shown) allowing the instrument string 45 to be moved along the borehole 65 . The instrument string 45 comprises a cable head 50 at the top end, which terminates the wireline 70 at the top; a well logging tool 60 at the bottom end;
[0022] and, a force sensing instrument 55 disposed between the cable head 50 and the well logging tool 60 . When run with wireline as shown in FIG. 1, the force sensing instrument 55 measures the tension force on the instrument string 45 . In other deployment configurations (not shown) the instrument string 45 may be run into the borehole 65 using coiled tubing or jointed pipe. In these situations, the force-sensing instrument 55 , measures both tension and compression forces on the instrument string 45 as it is pushed into the hole using the coiled tubing or jointed pipe. In addition, certain wireline deployment schemes use devices such as well tractors, crawlers, and other devices to push the instrument string 45 through highly deviated or horizontal boreholes. These pushing devices result in compression forces being imposed on the instrument string 45 .
[0023] [0023]FIG. 2 is a schematic of the force-sensing instrument 55 . The lower sub 25 is threadably adapted on its lower end to connect to the well logging instrument 60 . A connector 22 is mounted in lower sub 25 and provides electrical connection to a mating connector in the logging instrument 60 . Alternatively, the connector 22 may include provision for both electric wire and optical fiber connections. The connector 22 has typical o-ring seals 23 and 24 to seal the lower end of sub 25 against wellbore fluid intrusion. The upper end of lower sub 25 is threadably adapted to connect to strain gage sub 18 . 0 -rings 19 seal out wellbore fluid in the connection. Strain gage sub 18 has a reduced cross-section 32 on which strain gages 35 are disposed in a standard strain gage bridge arrangement. Strain gages 35 may be bonded gages or vapor deposited gages. Both methods are known in the art and are not described herein. Wires (not shown) from the strain gages 35 are fed through holes 37 and 38 and fed to the connector 22 .
[0024] The strain gage sub 18 is coupled with threads to a lower housing 15 , and the coupling joint is sealed with o-rings 19 . Lower housing 15 has a large internal bore at one end to provide clearance for the strain gaged section of strain gage sub 18 . A smaller seal bore is at the other end to allow passage of the load rod 14 and o-ring 17 seals the lower housing 15 against fluid intrusion. The load rod 14 is inserted through the bore and joined with threads to the strain gage sub 18 , and functions to transfer external forces to the strain gage body. The internal cavity 42 containing the strain gages 35 is thus sealed and isolated from the external environment in contrast to the typical oil-filled systems. The internal cavity 42 contains air, but may alternatively contain dry nitrogen or any chemically inert gas.
[0025] The load rod 14 , is configured with features critical to functional performance, as shown in FIG. 2 and FIG. 3. The thread 14 a is provided and suitably designed to connect the load rod 14 to the strain gage sub 18 , and to withstand the applied external forces. The diameters 14 b and 14 d function as pressure sealing surfaces, and are also designed and proportioned to effect a balance of hydrostatic pressure forces applied to the load rod 14 . The diameter 14 c is sized to provide mechanical shoulders as a means to transfer the external tension and compression forces. The internal diameter 14 e provides for mechanical clearance, and the diameter 14 f provides passage for electrical wiring and optical fibers.
[0026] The seal body 10 , (see FIG. 2 and FIG. 4) functions as an extension of the lower housing 15 , and provides a seal for the upper end of the load rod 14 and the top sub 1 . The critical design features of the seal body, shown in FIG. 4, are: the axial bores 10 a, 10 b, 10 c, the two external parallel flats 10 d, the two external windows 10 e which are perpendicular to the two flats, and the o-rings 10 f and 10 g. The bore 10 a is sized to clear the outside diameter of the pull rod. Together with the o-rings 10 f and 10 g, the bores 10 b and 10 c are proportioned to effect a pressure seal on the pull rod diameter 14 d and the top sub diameter 1 d, respectively. Parallel flats 10 d and external windows 10 e are proportioned and arranged to provide clearance for the tension links 13 , and access to the load rod 14 .
[0027] As a major point of novelty as compared to other systems, the bores and o-rings are proportioned and arranged to produce a balance of hydrostatic forces acting on the load rod 14 , as shown in FIG. 5. It can be shown that, considered as a free body, the load rod 14 is affected by hydrostatic pressure force vectors F 2 , F 1 , and F 3 . For free body equilibrium along the central axis, force vector F 2 must be equal to the sum of force vector F 1 and force vector F 3 , but opposite in direction. The interactions of the seal body 10 , the load rod 14 , and the lower housing 15 , cause the force vector F 2 to oppose the force vector F 1 . To enable the summation of force vector F 1 and force vector F 3 , a pair of tension links 13 are incorporated.
[0028] The tension links 13 are designed to pass through the windows 10 e of the seal body 10 to engage the respective shoulders on the load rod 14 , and top sub 1 . This is shown in FIG. 2 and FIG. 5. The load rod 14 is thus maintained in a state of hydrostatic equilibrium.
[0029] The pair of tensile links 13 are suitably proportioned to transmit the force vector F 3 and the external tension and/or compression force vectors. With the force vector F 3 applied, the load rod 14 is maintained in a state of hydrostatic equilibrium, and only the tension and/or compression force vectors are transmitted to the strain gage sub 18 .
[0030] In addition to the primary function, (to monitor and quantify the external tension and/or compression forces), the strain gage sub 18 is a structural member of the instrument.
[0031] Referring to FIG. 2, the upper housing 9 slides over the top sub 1 and the tension links 13 and threads into the lower housing 15 . As shown in FIG. 2, the inner diameter of upper housing 9 constrains the tension link 13 to remain engaged in the notches in the seal body 10 and in the top sub 1 . In FIG. 2, anti-rotation pin 8 fits through elongated slot, in the upper housing 9 and screws into top sub 1 , preventing rotation of the top sub 1 relative to the strain gage sub 18 . This prevents torque loading of the load rod 14 and the strain gages 35 and allows measurement of only the tension and compression loads on the system. Split collars 2 clamp around top sub 1 , as shown in FIG. 2, and are fastened together by screws (not shown) in threaded holes 3 . The split collars 2 are adapted to mate with threads in the cable head 50 . O-rings 4 seal out wellbore fluid. Electrical connector 6 is inserted in top sub 1 and provides for electrical and optical fiber connection with a similar connector in the cable head 50 . Threaded pin 5 fastens the connector 6 in position in top sub 1 and seal 7 provides a seal against fluid intrusion.
[0032] [0032]FIG. 6 shows another preferred embodiment exhibiting significant improvements in manufacturing cost and ease of assembly as compared to the preferred embodiment of FIGS. 2 - 5 . The seal body 10 and load links 13 of FIG. 2 are eliminated in the embodiment shown in FIG. 6. As shown in FIG. 6, load sensing tool 100 is connected to a wireline connection sub 101 through threaded connection 119 , thereby, transferring the axial load to top sub 110 . Alternatively, the load sensing sub 100 may be connected to coiled tubing (not shown). Both compression and tension loads can be transferred to load rod 114 through threaded connection 120 . The load is transferred from load rod 114 to gage sub 118 and then to lower sub 125 through threaded connections 121 and 122 , respectively. The lower sub 125 is connected to an instrument string (not shown). A compensating sub 110 is attached to the gage sub and stepped bores with seals 112 and 111 disposed on the inner circumference of the stepped bores. The bores and seals 111 and 112 are dimensioned to form a fluid seal with the load rod 114 . The load rod 114 also forms a fluid seal with seal 117 disposed in gage sub 118 . Cavities 131 and 132 are open to allow drilling fluid to enter the cavities 131 and 132 .
[0033] The interior of the tool 100 is filled with a gas at atmospheric pressure in direct contrast to typical downhole load tools that are oil-filled. The gas-filled tool has significant advantages over oil-filled tools. The strain gages in the oil-filled tools are subjected to bottom hole pressure which induces an error signal related to bottom hole pressure in the tool output. In addition, the oil ages and in many cases attacks and degrades the strain gages and the bonding agent fixing the gages to the load member. The cavities 141 and 142 and the wireway 143 are gas-filled. Port 130 connects the gas atmosphere to the area between seals 111 and 112 . The gas is typically air but may alternatively be dry nitrogen or an inert gas such as argon, helium, or the like.
[0034] Prior art tools have not used a gas filled sensor because the bottom hole pressure results in an axial load on the load sensor which results in a downhole pressure related error in the measurement of deployment forces. As described previously, the present invention uses predetermined sealing diameters on the load rod to balance the axial pressure forces and essentially eliminate downhole pressure as a source of measurement error. As a major point of novelty as compared to other systems, the bores and o-rings are proportioned and arranged to produce a balance of hydrostatic forces acting on the load rod 114 , as shown in FIG. 7. It can be shown that, considered as a free body, the load rod 114 is affected by hydrostatic pressure force vectors F 2 , F 1 , and F 3 . For free body equilibrium along the central axis, force vector F 2 must be equal to the sum of force vector F 1 and force vector F 3 , but opposite in direction. The interactions of the compensating sub 110 , the load rod 114 , and the gage housing 118 , cause the force vector F 2 to oppose the force vector F 1 . The forces are balanced when the sealed area defined by d 3 is equal to the difference in the areas defined by d 2 and d 1 . The downhole pressure acting on these areas cause the load rod 114 to be in static equilibrium.
[0035] Strain gages 135 are disposed on the load rod 114 for sensing axial deployment loads transferred through the load rod 114 . The instrumented load rod 114 provides for easy replacement should the load rod 114 and/or strain gages 135 be damaged. The gages 135 maybe bonded strain gages or vapor deposited gages known in the art. As the deployment loads are imposed on the load rod 114 , it experiences elastic strain, related to the load, that is detected by the strain gages 135 .
[0036] The foregoing description is directed to particular embodiments of the present invention for the purpose of illustration and explanation. It will be apparent, however, to one skilled in the art that many modifications and changes to the embodiment set forth above are possible without departing from the scope and the spirit of the invention. It is intended that the following claims be interpreted to embrace all such modifications and changes.
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A device to monitor and quantify the tension and compression forces acting on a well logging instrument string during deployment. The device eliminates the undesirable effects of downhole hydrostatic pressure on the sensors, and eliminates the need for a costly, complex, and high maintenance hydraulic pressure equalizing system in the force gage assembly. The device provides improved measurement accuracy, provides enhanced reliability and longer life of the sensors, and allows lower cost of manufacture and maintenance.
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[0001] This application is a continuation of a co-pending U.S. application Ser. No. 11/186,997, filed Jul. 20, 2005, which, in turn, is a continuation of U.S. application Ser. No. 11/014,321, filed Dec. 16, 2004, now U.S. Pat. No. 6,981,444 patented Jan. 3, 2006, which, in turn, is a continuation of U.S. application Ser. No. 10/110,356, filed Aug. 5, 2002, now U.S. Pat. No. 6,848,364 patented Feb. 1, 2005, which, in turn, is a section 371 of international application no. PCT/US00/28379, filed Oct. 13, 2000, which, in turn, is a continuation-in-part of U.S. application Ser. No. 09/419,493, filed Oct. 15, 1999, now abandoned.
[0002] This invention relates to blankets for printing presses and in more particular to blankets for printing presses using a pre-manufactured or pre-made blanket material which is then formed on a sleeve.
BACKGROUND OF THE INVENTION
[0003] Prior art seamless cylindrical or sleeved offset printing blanket technology is well known in the industry and documented in several patents, for example, those assigned to Heidelberg Harris (U.S. Pat. Nos. 5,323,702; 5,429,048; 5,440,981; 5,553,541; 5,535,674 and 5,654,100) and to Reeves Brothers Inc. (U.S. Pat. No. 5,522,315) the contents of all of which patents are hereby incorporated by reference. Two examples of the prior art seamless sleeved blankets 10 A, 10 B are illustrated in the schematic drawings of FIGS. 1 to 3 . FIGS. 2 and 3 are taken in sections parallel to the circular end of the roll. For ease of illustration, the curvature of the roll has not been shown. The FIG. 2 version 10 A contains two windings of spiral wound thread 12 A and is typical of blankets produced by Reeves and Day (for the Heidelberg presses). The 10 A version also has a sleeve 14 A, usually of nickel, the spiral wrapped threads 12 A, a compressible layer 16 A made of typically a rubber containing microspheres, a reinforcing layer 18 A carrying another roll of spiral wrapped threads 12 A, made of rubber with threads being cotton, polyester or other materials, and the printing layer 20 A having a printing face 22 A. Of course, the blanket including its sleeve actually curve around forming a continuous cylinder. FIG. 3 showing the version 10 B, contains only one winding of spiral thread 12 A and includes a thick rubber base layer 14 B. This construction is typical of Sumitomo produced sleeves for use on Mitsubishi presses. This seamless cylindrical sleeve has the inner nickel sleeve 16 B, a compressible layer 18 B which can be joined to the base 14 B by an adhesive layer 20 B. A printing layer 22 B is provided and has a printing face 24 B. Again, the sleeve 10 B actually curves around to form a seamless cylinder as shown in FIG. 1 .
[0004] In the prior art, cylindrical offset sleeved printing blankets, such as discussed above, are produced by spiral winding carrier and reinforcing threads 12 A/ 12 B helically around a continuous sleeve 24 A/ 16 B. The sleeve is usually coated with an adhesion promoting primer. A first layer of polymeric coated thread is spiral wound onto the coated sleeve by passing the thread through a dip tank containing the solvated and uncured polymeric material as it is spiraled around the rotating sleeve. Dispersed in the polymeric material of this first layer are hollow microspheres that provide compressibility to the finished blanket. The amount of the coating is typically controlled as the thread exits the dip tank through a restrictive opening which must be large enough to allow the microspheres to pass through while small enough to prevent excessive coating and the resulting inability to dry and set the polymeric material before sagging can occur. The coating is relatively thick such that the solvents must be evaporated very slowly prior to curing to prevent trapped gasses from blowing unwanted voids in the finished layer. The long evaporation time tends to slow down the production rate. The polymeric material is then cured. The resulting compressible layer is very rough, uneven and overbuilt, requiring grinding to the required dimensions.
[0005] The polymeric material applied by this method tends to maintain its form around the diameter of the thread resulting in unfilled valleys between this layer and the coated sleeve. This unfilled area leads to gauge loss (thickness or diameter loss of a finished blanket sleeve—which can result in loss of printing contact) in the finished product and is sometimes compensated for by carrying out the additional steps by spreading a filling layer of solvated polymeric material onto the coated sleeve with a doctor blade set up prior to winding of the coated threads. Of course, all of the polymeric material may be applied with a doctor blade set up, as a calendered sheet or other methods known to the art and the threads omitted or spiraled around or under the applied polymeric layer.
[0006] After grinding the first inner layer to the required dimensions, a second outer layer of polymeric coated thread is wound around the sleeve in a similar fashion to the first layer; however, microspheres are not included. This layer serves as a reinforcing layer and stabilizes the overformed printing surface. Again, the polymeric material may also be applied with a doctor blade set up, as a calendered sheet or other method known to the art and the threads omitted or spiraled around or under the thus applied polymeric layer.
[0007] The overlaid printing surface may be applied as a solvated polymeric compound utilizing a doctor blade set up or as a solid by several methods known to the art such as any known extrusion or calendering process. The completed composite is cross wrapped or otherwise held in place, then cured with pressure applied to the outer layer by several methods known to the art to mold and adhere all layers together. In the final step the cured composite is again ground to the required dimensions in such a way as to provide a surface profile conducive to ink transfer.
[0008] This process results in a cylindrical offset printing blanket that is completely seamless throughout all of its layers but requires every step to be carefully performed on an individual, sleeve by sleeve basis. Efficiencies associated with mass batching of component parts are very limited, if not impossible. It has also been found that cylindrical offset printing blankets produced by this method tend to draw in the width, wrinkle or crease the paper web during use resulting in unacceptable side to side registration through successive printing units. In the prior art, to overcome this deficiency the compressible layer is profiled in a convex manner during the grinding operation to provide a spreading effect on the paper web, further requiring the individual processing of each sleeve during this step in the manufacturing process.
SUMMARY OF THE INVENTION
[0009] This invention utilizes a pre-made or pre-manufactured, unitary flat offset printing blanket made by any of the methods known to the art of flat offset printing blanket manufacturing to produce, in mass, a unitized composite blanket covering which can be applied, in a seamed fashion, to a continuous supporting sleeve, such that the seam has a negligible effect on print length and gap bounce. The pre-made blanket material will contain requisite reinforcements which are generally layed out in a rectangular manner, and are not spiral wound. The seam is preferably parallel to the longitudinal axis of the sleeve and not skewed ideally by more than 1/16″ of inch for a plate of 1/16″ of inch plate gap to avoid registration and print length issues. For other size plate gaps one could use other tolerance but preferably not larger than the plate gap. The opposing ends of the flat blanket should butt together as closely as possible but preferably leave some gap to provide a good fit should cut blanket lengths vary, and the resulting gap should preferably be narrower than the plate gap of the press for which the sleeve is designed if it is to be aligned in that manner. In this way, the two gaps (one in the blanket—the other on the press plate cylinder) can be aligned during use so that there is no loss of print area or it is limited to the plate gap area. Alternatively, the seam can be made to coincide with any non-utilized area of a plate cylinder, such as, for example, in the trim margins of adjacent print areas.
[0010] The invention may include a blanket index, location or locking system or the like, which could use a pin and opening or other mechanism and insures that the blanket and plate gap (or other chosen area) always match perfectly. Preferably, the gap between the opposing ends of the blanket can be filled with a resilient and solvent resistant compound to minimize gap bounce and especially to prevent water and solvents from wicking into the ends of the blanket. If this wicking is not prevented, swelling and delamination would be expected to occur.
[0011] In use, installation time is maintained at a minimum by providing a blanket in cylindrical or sleeve form when installed on the press's blanket cylinder. By utilizing flat blanket technology, there is no need for special profiling to spread the paper web. The unitized composite blanket covering may also be purchased as a standard material available from any number of offset printing blanket manufacturers and applied to a continuous supporting sleeve according to the method of this invention.
[0012] The sleeve could be made of metallic, for example, nickel or steel, or non-metallic construction, say a solid, laminate or winding of films, such as mylar or thermoplastics. The use of a non-metallic sleeve is possible as there is no need to vulcanize or subject the product to high heat to cure during manufacture.
OBJECTS OF THE PRESENT INVENTION
[0013] It is the object of this invention to provide a seamed offset printing blanket that maintains the benefits of the prior art (maximized print length, minimized gap bounce and reduced installation time) while reducing manufacturing time and expense.
[0014] It is an object of the present invention to provide a seamed sleeved blanket for a printing press.
[0015] It is another object of the present invention to provide a method for making a seamed sleeved blanket for a printing press.
[0016] It is yet another object of the present invention is to provide a method for using the seamed sleeved blanket of the present invention.
[0017] A still further object of the present invention is to provide a seamed sleeved blanket in combination with a printing press.
[0018] Yet a further object of the present invention is to provide a combination of seamed sleeved blanket, printing press and indexing, locating or locking system.
[0019] Another object is to provide a seamed sleeved blanket which can utilize a non-metallic sleeve.
[0020] These and other objects of the present invention will become apparent from the following specification and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a schematic view of a prior art seamless blanket showing where the sections shown in FIGS. 2 and 3 are taken along the lines 2 / 3 - 2 / 3 (the slash meaning “or”).
[0022] FIG. 2 is a cross-sectional view of a segment of a prior art seamless sleeved blanket with the actual curvature being omitted for simplicity.
[0023] FIG. 3 is a cross-sectional view of a segment of a second prior art seamless sleeved blanket with the curvature being omitted for simplicity.
[0024] FIG. 4 is a schematic view of the seamed blanket of the present invention showing where the section shown in FIG. 5 is taken along the lines 5 - 5 .
[0025] FIG. 5 is a cross-sectional view of a segment of an embodiment of seamed blanket of the present invention, with the curvature being omitted for simplicity.
[0026] FIG. 6 is a schematic view indicating how a sheet of the pre-manufactured blanket material is wrapped around the sleeve to make the seamed sleeved blanket of the present invention.
[0027] FIG. 7 is a perspective view of the sleeve of the present invention showing how it may be notched to index or lock it into place with respect to a press's blanket cylinder.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0028] A schematic drawing of the seamed sleeved blanket 40 produced according to this invention can be seen in FIGS. 4 through 7 . As shown in FIG. 6 , according to this invention a conventional, flat offset printing blanket material 42 may be manufactured by methods well known to the art or purchased in roll form and cut to specific dimensions so that it can be wrapped (as indicated by the large arrows) as a solid sheet around a continuous supporting sleeve 44 to produce the seamed sleeved blanket 40 of the present invention and shown in FIG. 4 , the gap or seam being given numeral 45 . Referring to FIG. 5 , preferably the following construction method can be used. The blanket material 42 could be of any desired commercially available structure and could have a rubber surface 46 , say 0.023 inches thick over a first outer fabric layer 48 (reinforcement), say 0.009 inches thick, over a compressible layer 50 , say 0.014 inches thick, over a middle fabric layer 52 (reinforcement), say 0.011 inches thick, over an adhesive layer 54 , say 0.0002 inches thick, over an inner fabric layer 56 (reinforcement), say 0.015 inches thick. The sleeve could be metallic or non-metallic, and if metallic, preferably of nickel. The expandable nickel sleeve has been the sleeve of choice for sleeve offset blankets. There are alternative materials that can be used such as fiberglass, kevlar, plastic, and/or polyethylene (PET) sleeve. Some of these materials and particularly PET have several advantages over the nickel: lower cost, safer for the operator (no sharp edges), more durable than nickel in the manufacturing and pressroom environment. While the reinforcement shown was fabric, other conventional reinforcements could also be used. The sleeve 44 would be treated with a primer 58 , say 0.002 inches thick, and covered with a urethane or other adhesive 60 , say 0.002 inches thick, that bonds or adheres the blanket material 42 to the sleeve 44 . The across the roll dimension may be cut equal to or less than the length of the sleeve 44 and the around or circumferencial dimension may be cut equal to or no more than 1/16″ less than the outer surface length or circumference of the sleeve for use on a press with a plate gap of 1/16 of an inch. Of course, for other size plate gaps, this dimension could very. The ends 62 and 64 (of FIG. 4 ) of the flat blanket material 42 may also be cut or skived at an angle so that the ends meet in the seam 45 (indicated by the heavy double arrow in FIG. 5 ) generally flush from top 68 (outer surface) to bottom 70 (inner surface) (see FIG. 5 ) when wrapped around the sleeve 44 . The roll goods from which the cuts are made may be of any length and width common in the industry but should be maximized to provide the greatest number of cuts possible without excessive cutting waste. Manufacturing or purchasing in this form takes advantage of the efficiencies associated with mass production. It is well known that the wider and longer a roll of printing blanket material is produced, the less the cost per unit area.
[0029] The requirements of the flat offset printing blanket material 42 are the same as for any offset printing blanket and may vary according to the specific end use. A typical blanket physicals are: compressible layer 0.008 to 0.014 thick, stretch less the 1.25%, ply adhesion>2 lbs./linear inch, tensile stretch>300 pounds/linear inch, Shore A Durometer 70-85. Additionally, the printing face 72 usually will be overbuilt for grinding of the finished product to the required dimensions. The preferred printing blanket construction according to this invention is one containing one or more, but preferably, three plies 48 , 52 and 56 of reinforcing fabric bonded together with an adhesive or solvent polymeric resistant cement, preferably a nitrile cement is used. Alternatively, nonwovens, films or other supporting substrate, could be used instead of fabric. As the blanket material was pre-manufactured, the reinforcement generally will not be spiral wound but will run parallel and perpendicular at right angles to the center axis of the blanket cylinder axis and/or the axis of the blanket sleeve when installed on the blanket cylinder. It is believed that the absence of non-spiral windings in the present invention is beneficial to printing, keeping registration and avoiding web draw in. The blanket material should preferably contain a compressible or foam layer 50 between the two upper fabric plies 48 and 52 that is uniform in thickness across the width. This carcass construction should be in a range of 0.025 to 0.070, and preferably, approximately 0.055 inches in thickness. Of course other thickness could be used. A solvent resistant polymeric printing face 46 preferably made of nitrile or nitrile blends with other polymers is applied over the top ply of fabric and should be in a range of 0.010 to 0.070 and preferably no less than 0.044 inches thick so that the total gauge of the finished flat blanket is in a range of 0.030 to 0.110 and preferably approximately 0.096 inches thick.
[0030] After the individual pieces of blanket material 42 are cut to the appropriate size to fit around the sleeve, they are dried in an oven, for about 30 minutes at, for example, 150° F. to remove moisture or otherwise treated to remove moisture. Note, the blankets' sleeve is not subject to this drying, making the use of many non-metallic sleeve materials possible. The dried or moisture free blanket 42 is coated with a thin layer of self-curing polymeric material, preferably urethane 54 such as Por-A-Mold S-2868 manufactured by Synair. These self-curing urethanes are hindered by water so that moisture left in the blanket material 42 will prevent adequate cure and adhesion. The coated blanket is then wrapped around the sleeve 44 . The sleeve 44 has a thickness ranging from 0.002 to 0.010, and preferably 0.005 inches thick. The continuous sleeve may be made of suitable expandable or stretchable metal, and preferably nickel. The sleeve and completed blanket should be expandable or stretchable as that is the usual manner in which they are installed on a blanket cylinder. That is, the sleeve is expanded or stretched with air pressure to permit it to be so installed.
[0031] Other bonding materials may be used but often require heat activation. Application of heat to the already cured flat blanket can degrade its physical properties.
[0032] Nickel sleeves 22 are preferred but any sleeve, made of a rigid or semi-rigid material and having a Youngs Moduus and thickness that allows it to be expanded sufficiently to slip over the printing cylinder during installation and removal while retracting to fit the outer diameter of the cylinder tightly during use, may be used. As noted, it is possible to use non-metallic materials for the sleeve in the present invention as the sleeve never need be exposed to high temperatures. The sleeve dimensions must be chosen so that the interference between the inside diameter of the sleeve and the outside diameter of the printing cylinder on which it will be mounted prevents slippage around the cylinder during use. For example, 0.005 inch thick nickel sleeve should have an inside diameter of 0.002 to 0.020 less than the outside diameter of the blanket cylinder on which it will be mounted.
[0033] The sleeve 22 is first treated and primed (see FIG. 5 , numeral 58 ) in a manner common to the art and further coated with the self-curing urethane. The preferred primer is a single coat primer such as Pliogrip 6025, marketed by Ashland Chemical. Two coat primer systems may also be used.
[0034] The urethane or other coating is preferably applied to the back of the flat blanket by a doctor blade to completely fill the interstices of the fabric backing increasing the overall blanket thickness minimally or not at all. The urethane coating is applied to the sleeve by brushing but may also be applied by dipping, spreading with a doctor blade, spraying or other methods known to the art. The adhesive thickness may vary depending on the adhesive system used and should be consistent with the adhesive manufacturer's directions.
[0035] Hydrogenated nitrile rubber compounds have been successfully used in place of the urethane as solvated and spread adhesives or as calendered adhesive sheets. This method requires curing of the completed composite under pressure and at elevated temperatures while the urethane can be cured at room temperature. Of course, there are many other non-rigid adhesives that can be used to bond the blanket to the sleeve, such as acrylics or rubber based adhesives. They are only limited by the need for solvent and water resistance.
[0036] The ends 62 and 64 of the blanket are butted to each other such that the joint or seam 45 runs preferably parallel to the longitudinal axis of the sleeve. This butt joint should not be skewed by more than 1/16″ to prevent misregistration (see discussion above), short print, walking, or unacceptable movement of the printed web.
[0037] While being manufactured, to hold the flat blanket material in place on the sleeve, it may be secured in place with clamps and spiral wrapped with mylar or other tape under controlled tension (2-10 lbs./in.), removing the clamps as the tape spiral traverses the length of the sleeve. The mylar or other tape is butt or spiral would in such a way that successive wraps overlap one another sufficiently (5 to 95%—preferably, 40 to 60%) to apply pressure to the entire surface of the blanket. Alternatively, the blanket may be secured with adhesive tape prior to wrapping with mylar and/or the entire blanket may be enclosed in a mold that simultaneously holds the blanket in position and applies the appropriate pressure. The self-curing urethane cures and bonds the flat blanket to the primed nickel sleeve within 24 hours at room temperature. This cure rate can be accelerated with exposure to elevated temperatures, so long as those temperatures do not degrade the product. 150° F. is a good curing temperature that would reduce the cure time to about 8 hours. The mylar tape or mold is then removed.
[0038] This invention includes the concept of using a manufacturing fixture or mold to improve the manufacturing quality of the blankets. The idea is to use a device such as a manufacturing fixture or a mold that would allow the seam to be located, aligned precisely, and securely held during the curing process. The fixture would also apply even pressure on the surface of the blanket after it has been wrapped around the tubular sleeve. This replaces the manual method of “wrapping” the blanket prior to curing the bonding agent. The result is that the blanket quality can be reproduced consistently. The skill level of the manufacturing person is not as critical. It will also lend to automating the entire manufacturing process in order to reduce the cost and increase the quality. For example, the mold or fixture would be generally “C” shaped in cross-section and closed by over center clamps that pull the mold or fixture closed. That is, the “C” closes upon itself to form an “O”, with the blanket material sleeve in the center of the “O”. After the material cures, the blanket sleeve is released from the mold and finished, as by grinding on its outer surface.
[0039] The remaining gap 45 , if any, between the opposing ends of the blanket, can be filled with the urethane or nitrile material and allowed to cure adhering the two ends together and providing a suitable surface. The gap 45 should be filled with a resilient and solvent resistant compound to minimize gap bounce and to prevent water and solvents from wicking into the ends of the blanket. Of course, if the ends 62 and 64 are really a close fit or touching, then only sealing may be needed to prevent wicking, any such small or negligible gap not needing further filling.
[0040] It is also preferred that when used the gap filler material be of a different color from the blanket face so that the seam location is easily identified for proper alignment during installation. The same urethane is also utilized to seal the blanket materials 42 edges and prevent wicking into the sides of the blanket. The different color seam and a mark on the blanket cylinder could form part of an indexing system for properly locating the seam. Of course, another indicator than the seam could also be placed on the blanket cylinder and used with an appropriate mark on the blanket cylinder for indexing purposes.
[0041] Grinding to the appropriate diameter and surface roughness finishes the composite seamed cylindrical blanket. The diameter is specific to the press on which the sleeve will be used should be such that, in combination with the blanket's compressibility, excessive pressure does not cause slippage around the print cylinder. The appropriate surface roughness is achieved by selection of the face compound and grinding media. The “roughness average” (Ra) should be in the range of 0.2 to 2.0 microinches.
[0042] Prior art cylindrical blankets are typically built with a minimally thick composite covering the nickel sleeve. This results in excessive heat transfer to the cylinders on which they are mounted. During grinding, the heat transfer to the grinding mandrel can cause distortions requiring two stage or wet grinding. The blanket is first rough ground, allowed to cool and then finished. The thickness of the composite covering of this invention is such that heat transfer is negligible. Grinding may be accomplished in a single step and without the mess or capital expense associated with wet grinding.
[0043] According to this invention, multiple flat blanket pieces may be seamed together on a single sleeve for use on presses having multiple printing plates and thus multiple plate gaps. Such a blanket would have seams corresponding to the plate gaps and could be made to register with them. Also, according to the present invention any seam or seams on the sleeved blanket could be set up to fall in any corresponding area on the plate cylinder that did not interfere with useful printing.
[0044] The use of a mold to hold the flat blanket in position and apply pressure while the urethane cures allows for the possibility of using pre-ground or cast face blanket coverings. The impressions left by cure tapes/wraps require grinding of the finished sleeve, while the use of a mold leaves no such impressions. In this method, the gauge of the flat blanket material 42 covering and the outside diameter of the nickel sleeve control the outside diameter of the finished sleeve. Surface profiles are imparted in mass to the rolls of flat blanket material prior to cutting by methods well known to the art and reduce another unit by unit processing step.
[0045] The manufacturing costs associated with the prior art are high and the process is very slow. Output from the method of the present invention is three to four times higher than that of the prior art. And much of the auxiliary equipment such as blanket curing ovens, winding lathes, etc., are not needed. Production or purchasing of the blanket material covering in roll or flat form and large quantity significantly reduces the cost and individual seamed sleeves of the present invention can be completed at a rate of at least one every hour on the same machinery without the auxiliary equipment.
[0046] Unit to unit variations are common in the prior art. According to this invention, all seamed sleeves of the present invention produced from the same master roll of flat blanket material will be very consistent in properties.
[0047] In the prior art, there are no reinforcing or stabilizing threads in the horizontal direction. The threads applied in the circumferencial direction are not parallel to the end plane of the sleeve. It is possible that this thread orientation is responsible for the tendency to draw in the paper web during use and the consequent side to side misregistration from printing unit to printing unit. The seamed cylindrical blanket of this invention provides threads both perpendicular and parallel to the axis of the sleeve and no such registration shift issues occur. The need for profiling the compressible layer is not necessary.
[0048] Prior art seamless, sleeved or cylindrical blankets have historically slipped fractionally around the printing cylinder during use which causes print distortion. The proper combination of the blanket compressibility and finished outside diameter of the secured sleeved blanket of the present invention has been found to eliminate this slippage.
[0049] In addition, sleeves may be used in the invention that are made of plastic, rubber, fiberglass, kevlar or other suitable materials having appropriate elasticity characteristics. Since our invention requires no final vulcanization process, sleeve materials with softening point less than 300° F. can now be considered for use. This was not possible with cylindrical blanket made by the prior art.
[0050] This invention also provides for a sleeve to blanket cylinder lock up system. The lock up system guarantees that once the blanket is installed if will not slip circumferentially or axially on the blanket cylinder. This movement has been a problem with prior art. For example, a notch or opening 80 could be provided in the sleeve which cooperates with a raised portion or pin 82 (indicated in dashed lines in FIG. 7 ) on the plate cylinder. Other suitable two part mechanisms or male and female portions that fit together could also be used, one in the sleeve with the other in the plate cylinder. Should a full locking system not be desired or needed, the sleeve and plate cylinder could be provided with appropriate indexing marks to locate the seam in the desired area, be it in the plate gap or other non-utilized non-printing area of the plate on the plate cylinder of the press.
[0051] While the preferred form of seamed, sleeved blanket and method of making and using the same of the present invention have been disclosed and described, it should be understood that other equivalent steps and elements of those called for in the below claims fall within the scope of the appended claims.
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An offset lithographic printing press combined with a gapped or seamed cylindrical offset printing blanket having pre-made blanket material mounted on a cylindrical sleeve is disclosed, wherein conventional, manufactured blanket material in flat form is adhered to a cylindrical sleeve to economically produce a cylindrical sleeved blanket. The leading and trailing ends of the flat blanket material are joined in close proximity such that a small gap is formed. A seam may be made with a filler material that fills the remaining gap resulting in a seamed sleeved blanket. In use, the blanket's printing surface, which excludes the gap or seam, is aligned with the printing plate's image-bearing surface. Consequently, no loss of print length results from the gap or seam.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to the field of risk management. More specifically, the invention comprises a method and a system for extracting hazard information from forecast data having varied temporal and spatial accuracies.
[0003] 2. Description of the Related Art
[0004] Hazards and the use of hazard predictions are a significant concern for many industries, especially the aviation industry. Accordingly, the present invention is described and considered as it applies to aviation. The description of the related art will also refer generally to the aviation application. However, in reading this entire disclosure, the reader should bear in mind that the methods disclosed can be applied to many areas beyond aviation.
[0005] The general approach to hazard prediction in the aviation industry has been to utilize forecast data and other weather products which are commonly shared among various “users,” such as dispatchers, pilots, and controllers. Each of the users works to ensure that the aircraft avoids flying in unacceptably hazardous weather.
[0006] The weather information is generated by weather forecasters in various formats (textual, graphical, or as gridded values or probabilities in large increments of time). The weather may be “observations” of weather as it was at a particular time, which by the time of receipt is actually in the past. Alternatively, weather information may be supplied as “forecasts.” Forecasts are normally generated for periods of time into the future, again set in large increments of time (from several hours to several days). Forecasts generally describe the expected weather conditions rather than actual hazards.
[0007] These weather products in their current form require human interpretation. Furthermore, meaningful and accurate interpretation requires significant skill and experience. The aircraft operators are primarily interested in weather that will be dangerous to their aircraft operations and in weather conditions—such as winds and temperatures—that affect the efficiency of their flights. The users of the weather products therefore attempt to interpret meteorological data to find where hazards and favorable conditions exist. In addition, users typically need to access several different weather products and mentally integrate the information from them in order to develop a complete picture.
[0008] One common weather product is referred to as a Collaborative Convective-weather Forecast Product (“CCFP”). These forecasts often contain highly subjective values such as “confidence.” Such qualitative values are difficult to use as inputs for other tools. Such forecasts are often presented in large time increments, often in hours. The reason for the large time increment is the amount of automated and manual data processing that is required for the generation of the forecasts. The user receives many weather products, and these products are often not in agreement and are not for the actual time in which the user is interested. The user of these products therefore needs to have some meteorological knowledge to judge which of the products to believe, to interpolate between the times of effectiveness of the products, and then to generate an assessment of the level of probability of hazards implied by the weather forecast.
[0009] The further into the future the prediction is carried, the less certainty there is that the forecasts will be correct. This is especially true of convective weather forecasting. Convective weather is the source of turbulence, hail and lightning, all of which are hazards to aviation. The certainty of the forecast is normally expressed as a “probability” of the forecast weather occurring. With the convective weather forecasting example, this is stated in terms of “radar cloud tops,” and “likely percentage coverage of a several thousand square mile area” reader will note that the CCFP does not express probabilities of the hazards such as turbulence in objectively quantifiable terms specific to turbulence. Even when turbulence is forecast by some products it is in subjective values such as “moderate.” Of course, turbulence that is moderate for a large aircraft may be severe for a small one.
[0010] Users who are planning flights are required to identify hazards to the flight and attempt to quantify them and their affect on their aircraft. However, the user is presented with conflicting views of weather from the various data sources. The large time between forecast updates is also a problem, since a first available forecast may be for a point in time one hour before the flight passes a point and the next forecast an hour after the flight has passed.
[0011] FIGS. 1 and 2 illustrate the problem of using historical weather data. FIG. 1 shows weather data for the continental United States at the flight planning stage. Aircraft 16 is to fly from Los Angeles, Calif. (denoted as origin 12 ) to Atlanta, Ga. (denoted as destination 14 ) along planned route 10 . The dispatcher typically evaluates the route approximately 1 hour before takeoff. The weather data may be 30 minutes old when the dispatcher evaluates the route. The weather data of FIG. 1 illustrates a moving storm front 18 with associated storm cells. Storm front 18 intersects a portion of planned route 10 at the time the weather was observed.
[0012] As shown in FIG. 2 , by the time aircraft 16 is within 2 hours of destination 14 , storm front 18 has moved beyond destination 14 . In this example, the dispatcher may have correctly predicted that planned route 10 would avoid storm front 18 .
[0013] In the example illustrated in FIGS. 1 and 2 , the dispatcher used radar data as proxies for hazardous weather conditions. Weather data is not always a reliable proxy for predicting a hazardous condition. Radar returns generally show raindrop density. As illustrated in FIG. 3 , a radar return illustrates the presence of storm cell 20 and storm cell 22 . Regions 30 denote areas of heaviest rain. Regions 28 , 26 , and 24 illustrate heavy rain, moderate rain, and light rain respectively. An inexperienced dispatcher viewing weather data as proxies for hazardous conditions might look at such a radar return and determine that flying between storm cell 20 and storm cell 22 would be the safest route. Severe turbulence zone 34 actually exists between storm cell 20 and 22 —an area the proxy data suggests should be free and clear of hazardous conditions. In addition, hail can be blown well clear of the hazard area indicated by the proxy as illustrated by potential hail zones 32 .
BRIEF SUMMARY OF THE INVENTION
[0014] The present invention comprises a new method and system for generating probabilities of objective values of hazards as a fine granularity grid in four dimensions (three spatial dimensions plus time) to be used by decision support and visualization tools. Utilizing the proposed system, weather data received at different times and in different formats may be used as input data to create a fine four-dimensional grid of intelligent software agents. The method allows for proxies and/or subjective information on hazards that may arrive asynchronously and with poor temporal and spatial accuracy to be converted into a standard four-dimensional hazard probability grid. The grid is created automatically, without the need for expert human interpretation.
[0015] The data assimilation and conversion is performed by intelligent software agents. These agents convert the input data into hazard probabilities at one or more four dimensional points. These points are represented as nodes in a four dimensional matrix. Each node communicates its current hazard probabilities to its neighbors in space and time. The neighboring nodes ensure that the probability gradient and probability density functions follow the correct rules for the hazard type in the current or future environment. The result is that information on a proxy for a hazard is translated into a hazard probability of an objective value of the hazard at a point on the four dimensional grid. The probability values for that hazard objective value for all the neighboring points then change to represent the correct probability gradient.
[0016] This approach integrates the input information and the users decision support tools so that the user may easily search the four-dimensional grid for four dimensional ‘volumes’ of high probability of hazards and choose the least-risk path through the four-dimensional matrix. The grid is updated with each asynchronous observation or forecast product input and generates the hazard probability grid at regular and frequent intervals. The hazard probability grid can be used to provide visualizations of the hazard levels for display to the users.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0017] FIG. 1 is a graphical depiction of a planned route and historical weather data.
[0018] FIG. 2 is a graphical depiction of a planned route and historical weather data.
[0019] FIG. 3 is a graphical depiction of a radar return.
[0020] FIG. 4 is an illustration of a three-dimensional grid of software agents.
[0021] FIG. 5 is a detail view of a three-dimensional grid of software agents.
[0022] FIG. 6 is an illustration of a simplified two-dimensional grid for determining the probability of rainfall.
[0023] FIG. 7 is an illustration of a portion of a grid representing a geographic region adjacent to a mountain.
[0024] FIG. 8 is a graphical display, illustrating a volumetric representation of a weather hazard.
[0025] FIG. 9 is a two-dimensional risk projection for a jetliner and a general aviation aircraft.
[0026] FIG. 10 is a three-dimensional representation of terrain and probabilistic weather hazards.
[0027] FIG. 11 is a three-dimensional representation of terrain and probabilistic weather hazards.
[0028] FIG. 12 is a three-dimensional representation of probabilistic hazards and an aircraft route avoiding the hazards.
[0029] FIG. 13 is a three-dimensional representation of probabilistic hazards and an aircraft route avoiding the hazards.
[0030] FIG. 14 is an illustration of the effect of terrain on a radar coverage zone.
[0031] FIG. 15 is an illustration of how terrain may be used to avoid radar detection.
[0032] FIG. 16 is an illustration of how terrain may be used to avoid radar detection.
[0033] FIG. 17 is a section view, showing the internal details of a volumetric representation of a probabilistic weather hazard.
[0034] FIG. 18 is an illustration of a container ship encountering waves and wind.
[0035] FIG. 19 is a graphical display, showing two-dimensional representations of probabilistic hazards and a route to be followed by a container ship to avoid the hazards.
[0036] FIG. 20 is a diagram, illustrating the input of data into a four-dimensional grid.
[0037] FIG. 21 is diagram, illustrating the regular export of the probability values from the four dimensional grid to a data store.
[0038] FIG. 22 is a diagram, illustrating the interface between decision support tool applications and a data store.
[0000]
REFERENCE NUMERALS IN THE DRAWINGS
10
planned route
12
origin
14
destination
16
aircraft
18
storm front
20
storm cell
22
storm cell
24
region
26
region
28
region
30
region
32
potential hail zone
34
severe turbulence zone
38
grid
40
node
42
local peak
44
altitude
46
jetliner
48
general aviation aircraft
50
risk exceedance zone
52
terrain hazard
54
weather hazard
56
combined hazard
58
traffic hazard
60
terrain hazard
62
risk aversion scale
64
instantaneous risk aversion
66
radar installation
68
radar coverage zone
70
terrain
72
altitude AGL
74
icing hazard
76
turbulence hazard
78
container ship
80
wave crest
82
land
84
wave/wind hazard
86
shallow hazard
88
observed/reported information
90
conversion software
92
grid
94
export process
96
data store of hazard values
98
application program
interface
100
DST applications
102
low visibility hazard
DETAILED DESCRIPTION OF THE INVENTION
[0039] FIGS. 20-22 show an overview of a process for generating a four-dimensional hazard probability grid for predicting locations of hazardous conditions and providing hazard probability data to a user in a useful form. FIG. 20 shows a schematic depiction of a grid, with individual points or nodes in the grid being shown as ovals. The process generally involves assembling forecast and observed/reported information 88 and manipulating these input data using conversion software 90 to create probabilities of objective values of hazards as an input into the fine granularity, four-dimensional probabilistic agent grid 92 . Observed/reported information 88 may include information from observations and predictions arriving asynchronously for any time period and any three-dimensional position in the grid of hazard data. Observed/reported information 88 is usually reported in large time and spatial increments. As an example, observed weather information is often reported in hourly increments for controlled airports with forecasts every six hours. The present invention manipulates these data and presents them in a fine spatial and temporal grid which is a more readily usable format for the Decision Support Tools.
[0040] FIG. 21 shows how the hazard grid data is exported for use in decision support tools. Grid 92 is a simple four dimensional data array of hazard objective values and associated probabilities. The grid is regularly updated and the values stored in the grid are then exported to data store of hazard values 96 via export process 94 . This four-dimensional hazard data is maintained in data store of hazard values 96 so that the hazard may be further transmitted to the recipients' decision support tool (“DST”) applications as will be described in greater detail subsequently.
[0041] There are many applications for which four-dimensional representations of hazards are useful. For example, it may be used to forecast probabilities of hostile troop movements or certain types of weapon systems. The decision support tools may incorporate this forecast information to identify the type of approach which is most likely to avoid engagement or detection. It may also be used to forecast the effect of a hazardous material explosion on an area. The decision support tools may be configured to forecast areas that would be safe for emergency response teams from building debris and nuclear/biological/chemical results of the explosion. Many other applications are possible, but for greater clarity the description will first focus on the implementation of four-dimensional representations of aviation hazards for use in decision support tools.
[0042] As mentioned previously, the process has as its input any or all normal forecast and observed/reported information 88 . This information may already be “gridded” but typically at large temporal and spatial intervals (such as with the Rapid Update Cycle weather model). The information may be graphical and textual, showing a probability of an event or proxy event in the future (such as forecast radar echo tops and forecast composite reflectivity in a CCFP). This information requires translation into the probability of one or more hazards for which they are a proxy. This translation is performed by conversion software 90 . For example, high radar echo tops and high radar reflectivity are used as proxies for the presence of turbulence, hail and lightning.
[0043] Observed/reported information 88 may also be in the form of specific reports of a hazard, such as a pilot reporting severe clear air turbulence. Accordingly, the imported data may include data of the following types:
[0044] 1. textual reports of actual hazard occurrences and their subjective or objective values;
[0045] 2. numerical reported data for a small area;
[0046] 3. gridded data that covers all or a subset of the grid but at a coarser spatial and temporal resolution (These values may need to be converted to hazard probabilities and interpolated to the grid points); and
[0047] 4. graphical data that requires interpretation, such as a probability boundary (This could be the CCFP warnings) or a Significant Meteorological (SIGMET) Advisory in aviation terms; or even a synoptic forecast chart.
[0048] As shown in FIG. 20 , conversion software 90 reads each observation or forecast information type and converts the information into four-dimensional probabilities of objective hazard values (three spatial dimensions plus time). In doing so, conversion software 90 identifies the time and place of these probabilities. As an example, a report on existing conditions at a point will have a probability of 1 (100%) whereas a forecast of the same conditions at that point but several hours into the future may have a maximum probability of 0.6 (60%) due to the known inaccuracy of forecasting that hazard.
[0049] Accordingly, conversion software 90 is concerned with the conversion of:
[0050] 1. deterministic values to probabilistic values;
[0051] 2. subjective values to objective values; and
[0052] 3. graphically displayed proxies for the values of concern and proxy forecasts to the four dimensional probabilities of objective values of hazard.
[0053] FIG. 20 shows the asynchronous input information as observed/reported information 88 . Conversion software 90 converts this information and input these values to the agent(s) in the correct four-dimensional position in four-dimensional probabilistic agent grid 92 . The agents in the grid represent a particular three-dimensional point in space at a particular instant in time. The values at that point are updated for each step into the future. The point in space represented by the agent will have influences from the geography around that point. This geographical factor can be held as a set of rules for how particular hazards affect that point in space. For example, in the aviation case, a point in space that is just downwind of a mountain may always set a probability of turbulence based on the wind direction and speed, even without an external input. In addition, a point in space that is inside a mountain would have a probability of 1 (100%) of hazard to aviation all the time.
[0054] FIG. 4 illustrates a small number of intelligent agent nodes on the four-dimensional grid, with an indication of the communication of probability and state changes between the nodes. The actual grid would consist of a three-dimensional grid of intelligent software agents (or “nodes”) representing the entire volume of airspace. The fourth dimension of time would be included by creating a set of three-dimensional grids for each time period out to the future time limit of forecasting. In the example shown in FIG. 4 , grid 38 is a three-dimensional grid with nodes 40 corresponding to locations in three-dimensional space separated by five nautical miles in a North/South/East/West grid and one thousand feet in altitude. There may then be a three dimensional grid for each 15 minutes from 15 minutes in the past out to 12 hours in the future. Other granularities for time and space may also be used.
[0055] Parameters are defined for each node 40 on grid 38 . Rules are also defined to govern the interaction of each node with neighboring nodes. These “rules” are preferably modifiable, so that the grid can “learn” as it accumulates data over time. The term “neighboring node” generally refers to a node that is adjacent to the reference node on the three dimensional grid. In the present example, a neighboring node is a node corresponding to a location in space that is approximately 5 miles from to the point in space corresponding to the reference node.
[0056] Multiple existing predictive models can be fed into each node. In the weather hazard example, these would be weather forecasting models. These weather forecasting models may be updated every 15 minutes or when new data is input into grid 38 . For example, the grid may be updated when a pilot observes and reports turbulence or icing at a location or wind gusts are observed on the ground.
[0057] FIG. 5 shows a detailed view of a portion of grid 38 . As mentioned previously, each node 40 in grid 38 represents a point in space and time. Each node has a set of parameters. Each link between adjoining nodes includes a set of rules describing how the neighboring node relates to the reference node and vice versa. It is preferably that some of the parameters to be stated in terms of the probability of a condition existing at the point in space represented by the node. For example, while pressure and temperature may be actual fixed values, actual hazards such as precipitation, icing conditions, and turbulence can be given as probabilities. When node 40 receives a probability of an objective value and possibly a probability skew definition, either from a neighboring agent or from an input agent, the agent uses the rules to first set the probability of that objective value at the point it represents and then send a probability of an objective value and the probability skew if necessary to its neighbors in time and space. Those that are skilled in the art will appreciate that the computer implementation of this logic may differ in order to achieve a greater processing efficiency.
[0058] FIG. 6 is a very simple two-dimensional grid example showing how a probability of a condition “ripples through” the grid. At time t 1 , rain is observed at the location corresponding to node N 1 . The fact that it is actually raining at node N 1 increases the probability of rain at nodes proximate to N 1 including nodes N 2 , N 3 , and N 4 . The probability of rain at each node at time t 1 is illustrated by the bar graphs above each node. At time t 2 , the probability values for precipitation change at N 1 , N 2 , N 3 , and N 4 in accordance with the rules prescribed by the weather forecast models embedded in each node 40 .
[0059] The concept of nodes 40 passing probabilities of objective hazard values and skews between each other may be modeled as a Petri-Net which consists of “places,” transitions, and arcs that connect them. The places pass values and transitions between them, and in the present example, the places represent actual three-dimensional positions at a particular time. If a Petri-Net model is used, each node 40 represents a single intelligent node or agent at a four-dimensional position on the grid. It receives change of state input(s) from another node that first received information. Each node 40 , when given the probability of an objective hazard value, pass their new values to their neighboring agents in space and time via continuous/logical change of states.
[0060] As time passes, the intelligent agents representing the nodes in the four-dimensional grid and their associated hazard data move into the past. The intelligent nodes can then compare their hazard values with the actual values and the values that were forecasted. The intelligent nodes then construct the new intelligent agents in the future for their three-dimensional position and include, if necessary, corrective parameters for future input values from forecasts and inputs from particular input agents.
[0061] FIG. 7 illustrates how the “rules” governing the behavior of nodes may be updated over time to “learn” from observed trends. Local peak 42 corresponds to a mountain peak. Actual reports for that position may establish the fact that with particular wind directions, there is always a level of turbulence. A west wind will tend to produce turbulence proximate the nodes that are downwind of local peak 42 . Thus, when a west wind is observed, a higher probability of turbulence would be predicted at nodes N 2 , N 3 , and N 8 . There are more complex formulae that are used in meteorology that could be applied to inputs from particular types of forecasts and ensemble forecasts.
[0062] Various algorithms may be employed to implement such “corrections” to the embedded models. In one example, the actual values of the hazards at the present time are returned to the intelligent agents that had made forecast inputs to the grid. These values will allow the input agents to correct their Bayesian trust levels in the probabilities that are generated.
[0063] Referring back to FIG. 21 , on a periodic basis, or when a particular threshold value is passed, four-dimensional probabilistic agent grid 92 exports the probabilities of objective hazard values into data store of hazard values 96 . This database holds the four-dimensional grid of the probability of objective hazard values. The database is said to store the information in fine granularity. “Fine granularity” means that the spatial and temporal resolution of the information must be suitable for the user's applications and decision support tools. In the aviation meteorological hazard example, the decision support tools would preferably utilize hazard probability data with time increments of no more than 15 minutes and spatial increments of 5 miles latitude and longitude and one thousand feet altitude.
[0064] A different resolution may be better suited to a non-aviation application. If a nautical system were used as an example, the granularity in miles may be ten nautical miles with the vertical dimensions being in ten feet increments limited to an altitude up to 500 feet above the sea surface and temporal granularity of thirty minutes. Also, other hazards may be required such as wave height.
[0065] As illustrated in FIG. 21 and described previously, grid 92 , which contains the calculated values of objective hazard value probabilities, is exported to data store of hazard values 96 . The data may then be accessed for use by decision support tools. FIG. 22 schematically depicts this data extraction. Decision support tool applications 100 , which may include simple visualization tools, may access the data store of hazard values 96 via application program interface 98 . The data interface describes the format of the data and the subscription method to be used. As the quantity of data will be large, decision support tool applications 100 may be configured to subscribe to a small segment of the data from the data base that covers their areas of interest (such as a limited geographic region).
[0066] Accordingly, application program interface 98 includes a subscription mechanism to allow decision support tool applications 100 to interface with the data store. The subscription mechanism can be further configured to allow the decision support tools to receive automatic updates of information, to limit the amount of the information that they require, or to limit the type of hazard that they require. Decision support tool applications 100 may be further configured to find the least hazardous route through the area of the real world represented by the four-dimensional grid of data. This functionality will be described in greater detail subsequently.
[0067] FIG. 8 is a graphical depiction of a weather hazard, storm cell 20 , occupying a three-dimensional space at a designated time. Storm cell 20 has tops at 28,000 feet. Storm cell 20 would appear as a substantial hazard on a conventional weather plot (where radar returns are used as a proxy for a hazard). However, since transcontinental jetliner 46 is flying at 38,000 feet, storm cell 20 does not pose a hazard to it. On the other hand, general aviation aircraft 48 has a service ceiling of 12,000 feet. Thus, general aviation aircraft 48 should attempt to avoid the hazard posed by storm cell 20 .
[0068] FIG. 9 illustrates vehicle-specific, two-dimensional risk projections of the hazard shown in FIG. 8 . In the risk projection for jetliner 46 , no hazard appears since storm cell 20 is well beneath the cruising altitude of jetliner 46 . The two-dimensional risk projection for general aviation aircraft 48 reveals the hazard as risk exceedance zone 50 . This depiction reveals to the pilot or dispatcher that the trajectory of general aviation aircraft 48 should be altered to avoid the hazard.
[0069] FIGS. 10 and 11 illustrate how multiple hazards may be combined into a single, integrated display. The left view in FIG. 10 shows terrain hazards 52 as a function of altitude 44 . Terrain hazards 52 may be mountain peaks, skyscrapers, or other ground-based hazards. The right view in FIG. 10 shows weather hazards 54 as a function of altitude 44 . Weather hazards 54 reveal areas where there is a high probability of turbulence, hail, or lightening. FIG. 11 shows the combination of weather and terrain hazards as combined hazard 56 . These are four-dimensional plots which show increasing risk the further one travels into the hazard zone. The reader will note that in FIG. 11 , combined hazard plots 56 are shown relative to risk aversion scale 62 . In most cases, risk aversion scale 62 correlates with altitude. The concept of navigating through such terrain is familiar to aviation personnel and the decision support tools may utilize common algorithms for terrain following. The area/time described can be considered as a topographical probability density surface. The trajectory should fly a safe separation “above” the probability values. The safe separation is a function of the physical safety and the risk aversion of the users. Using such a display, an avoidance path may be chosen which avoids high hazard probabilities by a defined risk aversion factor.
[0070] Although risk aversion scale 62 most often correlates with altitude, this is not always the case. For example, the most common avoidance to icing conditions is to descend to a lower altitude. “Icing” refers to a phenomenon when an aircraft's wing begins to accumulate ice. The accumulated ice both adds weight to aircraft and changes the shape of the airfoil. If the airfoil accumulates enough ice, the aircraft may stall.
[0071] In an actual display, the display of combined hazard may be modified from FIG. 11 to show combined hazard 56 as a function of altitude (instead of risk aversion scale 62 ). In such a display, combined hazard 56 may appear as hazard of varying intensity (e.g., depicted by different shades of color). In one example, terrain hazards may appear in bright red since it would never be acceptable to fly through terrain. Precipitation or light turbulence, however, might not be a significant hazard to a particular aircraft or pilot. Less significant hazards and areas where hazard probability is low may be illustrated in lighter shades or alternate colors. This feature allows a pilot to consider his or her personal risk tolerance when evaluating whether to penetrate a hazard region or avoid the region altogether. For example, a corporate pilot may be willing to fly through significant weather hazards to pick up the company's CEO on time, but may prefer to alter the return route to provide a smooth route when the pilot's boss is on board.
[0072] FIGS. 12 and 13 shows a graphical depiction in which the hazard probabilities are visually presented as volumes of space. FIGS. 12 and 13 illustrate the same aircraft trajectory, planned route 10 , from different perspectives. Several hazards are illustrated in the display including, terrain hazards 60 , traffic hazard 58 , and weather hazards 54 . Planned route 10 is marked with time intervals to indicate the approximate time the aircraft will pass through the point in space if planned route 10 is followed. Traffic hazards 58 indicate areas where there is a high probability of aircraft traffic around the airport. Traffic hazards 58 correspond to the approach and departure vectors for the airport. These hazards get “taller” and more “diffuse” further from the airport. Weather hazards 54 are shown in the distance. These volumes represent anticipated weather at these locations several hours in the future. Future weather hazards may appear larger and less distinct, because of increasing uncertainty as one looks forward in time. Terrain hazards 60 remain static over time. FIG. 13 better illustrates the relationship of risk aversion scale 62 . The vertical lines under planned route 10 illustrate the instantaneous risk aversion 64 of the aircraft at a series of points along the aircraft's trajectory.
[0073] Those skilled in the art will realize that the graphical depiction of weather hazards 54 in FIGS. 12 and 13 are based on certain assumptions of time—namely that the aircraft follows the planned route at the planned time and speed. In order to create the avoidance path, the aircraft's performance must be known and considered. If the aircraft slows down or enters a circular hold at some point rather than continuing along its projected path, the hazard probability “mountains” will change and a new avoidance path may need to be determined.
[0074] FIGS. 14-16 illustrate how the present invention can be used in military applications to assist military aircraft avoid radar detection. FIG. 14 illustrates radar coverage zone 68 for ground radar installation 66 . Radar coverage zone 68 is limited by terrain 70 and altitude. FIG. 15 shows how a military aircraft can fly a route (planned route 10 ) using terrain 70 to make its way between two radar installations 66 . FIG. 16 shows how the display can be used to plan an appropriate route. In this illustration, altitude above ground level (“AGL”) 72 is illustrated by vertical lines beneath planned route 10 . Altitude AGL 72 indicates the successive altitudes attained by an aircraft flying along planned route 10 . Of course, weather hazards may also be added to the display. The pilot or planner may then use vehicle-specific or mission-specific parameters to control the display. As an example, if the radar sites control known surface-to-air missiles (SAMs), the pilot or planner might be willing to risk severe weather to avoid radar detection.
[0075] FIG. 17 is illustrates a “layered” hazard display. The hazards have been cut (a single planar slice) in this view to show to show the internal details of the hazard. Terrain 70 has no internal details since flying through part of terrain 70 is never acceptable. The weather hazards, however, have internal details. It is preferable that these internal details be indicated by varying color or labeling. FIG. 17 shows general aviation aircraft 48 approaching a weather hazard along planned route 10 . Low visibility hazard 102 indicates a risk of clouds and light rain. The aircraft can fly through these conditions, but icing hazard 74 and turbulence hazard 76 pose significant risk to general aviation aircraft 48 . Even if the aircraft can safely fly through low visibility hazard, it is possible that the pilot is not trained for flying in such conditions. A non-instrument rated pilot can only legally fly through VFR (visual flight rule) conditions. Significant areas of low visibility are known as IMC (instrument mandated conditions). Thus, if the subscribing pilot is a non-instrument rated pilot, the whole hazard would not have any interior features and the pilot would be informed that he must avoid the weather hazard altogether. If, on the other hand, the pilot is instrument rated, the display would show a safe route through the weather hazard.
[0076] The decision support tool applications may be further configured to evaluate planned routes and suggest alternate routes where the planned route is likely to encounter a hazard which exceeds the operator's risk aversion for the hazard. In order to do this, the decision support tools require as inputs (1) the objective hazards that the vehicle must avoid to be safe, and (2) the probability of those hazards that the operator of the vehicle can accept or not accept. The operator may add a value of avoidance for particular probabilities that defines that operator's risk aversion for that hazard. So if the operator selects a trajectory and there is a probability of 70% at a point for a hazard for which the operator has stated a 50% “clearance” is needed (i.e. a maximum of 50% probability of that hazard can be accepted), the decision support tool may indicate that the trajectory is unsafe and/or may recalculate a different route with lower probability of hazard. Sometimes this change may be a delay in departure which maintains the original three-dimensional trajectory if the delay causes the probability of hazard to drop to within an acceptable range.
[0077] To identify an acceptable trajectory through the four-dimensional grid of hazard probabilities, the decision support tools define the initially proposed trajectory through that grid in four dimensions. The decision support tool can be configured to “know” the maneuvering capability of the aircraft in climb, descent and turn, and may investigate hazard probabilities that are above, below, left and right of each point on the trajectory and which can be reached in a period of time. The probabilities of hazards around the trajectory may be considered and the decision support tool may define a trajectory that attempts to remain in the ideal “probabilistic values.” If the trajectory cannot remain within the parameters defined by the user, then the trajectory cannot continue in a particular direction and will need to be re-routed earlier to avoid the hazards.
[0078] It is preferable that the representations of hazards displayed on decision support tools be vehicle-specific. FIGS. 18 and 19 illustrate an example of a hazard display for container ships. This particular example considers hazards that might affect container ship 78 . In FIG. 18 , waves, identified as wave crests 80 , are approaching container ship 78 from the North-Northwest while the wind is approaching from the North-Northeast. Container ship 78 has specific characteristics (including length, width, center of gravity, rolling characteristics) which make it vulnerable to certain wind and wave combinations. It should be noted that some conditions which are safe for a large ship may pose a greater danger to a smaller ship, and vice versa. For example, certain long ships (such as container ship 78 ) are more vulnerable to waves having a long crest-to-crest distance than shorter ships.
[0079] FIG. 19 shows a two-dimensional hazard plot for the container ship example. Because a watercraft cannot alter its altitude like an aircraft, a two-dimensional display is sufficient to show the hazards relevant to the watercraft. The watercraft operator is only concerned with hazards that may exist around sea level. As shown in FIG. 19 , land 82 and shallow hazard 86 indicate terrain hazards. These terrain hazards are generally static except to the extent that the tide level influences the shape of shallow hazard 86 . Wave/wind hazard 84 is much more dynamic. As shown in FIG. 19 , the planner is able to use the display to determine planned route 10 for container ship 78 which avoids potential hazards that are of concern to container ship 78 . If conditions change differently than anticipated, the route may be altered to avoid the projected location of the hazards.
[0080] Referring back to FIG. 22 , decision makers using DST applications 100 obtain data for the hazard displays via application program interface 98 . The amount and type of data transmitted to DST applications 100 can vary based on (1) the resources available to DST application 100 , (2) the nature of the hazards of concern to the decision maker, and (3) the level of decision autonomy desired by the decision maker. On one extreme, an inexperienced pilot may simply want a display of potential hazards that are in the general vicinity of his planned route. In this example, the inexperience pilot visualization application may require the hazard data to be pre-processed to the level of an image or video feed. This particular pilot and aircraft may therefore have one type of subscription in which only processed image data is transmitted to the visualization tool.
[0081] On the other extreme, a military aircraft may want hazard data that includes specific hazard parameters or risk models. The DST application used by the military decision maker may be capable of processing the hazard parameters and risk models to optimize routes and generate displays based on the risk models and parameters. In the military context it may be preferable for the determination of hazards and evaluation of routes be performed independently by the decision maker's DST. The military aircraft would therefore utilize a different type of subscription than the inexperienced pilot of the previous example.
[0082] It is further contemplated that the transmission of hazard data be updated continuously, at designated time intervals, or when new input data is received by the grid. Also, new data may be transmitted when the vehicle deviates from its originally planned trajectory. For example, if an aircraft does not depart at the planned time, new hazard data may be acquired to update the display. Thus, the timing of data transmissions may be varied as required as needed for the particular application.
[0083] Referring back to FIG. 20 , conversion software 90 is used to convert observed/reported information 88 into data that can be input into grid 92 . Observed/reported information 88 includes many currently available weather products. Thus, conversion software 90 employs processing algorithms which are capable of converting data from existing weather products into deterministic values which can be fed to grid 92 . These processing algorithms will vary depending on the particular weather product that is used. For example, radar returns detailing raindrop density for a particular geographic region may be fed directly to conversion software 90 . Conversion software 90 then can correlate the raindrop density data to specific nodes on grid 92 at the time of the radar return. Drop density values may then be applied directly to grid 92 as a parameter. Alternatively, drop density data may be pre-processed using known meteorological models to compute other hazard parameters to be fed into grid 92 .
[0084] Although the preceding descriptions contain significant detail, they should not be construed as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. As an example, although the description details how probabilistic forecasting can be used for weather hazards, the same principles can be applied to other aviation hazards such as SAM (Surface to air missile) sites in a combat environment and to hazard prediction in non-aviation related industries such as frost or heavy rain affecting the construction industry. Accordingly, the scope of the present invention should be defined by the claims and not the examples given.
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A new method and system for generating probabilities of objective values of hazards as a fine granularity grid in four dimensions (three spatial dimensions plus time) to be used by decision support and visualization tools. Utilizing the proposed system, proxies for hazard data received at different times and in different formats may be used as input data to a grid of intelligent software agents which generate a four dimensional matrix of probabilities of objective values of hazards. The method allows for proxies and/or subjective information on hazards that may arrive asynchronously and with coarse temporal and spatial accuracy to be converted into a standard fine granularity four dimensional hazard probability grid. The grid is created automatically, without the need for expert human interpretation, can provide visualization of the four dimensional hazard volumes and may be used directly by decision support tools without the need for expert human interpretation.
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FIELD OF THE INVENTION
Background of the Invention
The invention relates to a retaining member of a plastic material which is useful for holding lines on a support.
SUMMARY OF THE INVENTION
When pipes, flexible tubes, and other lines through which pressure pulses are transmitted are mounted on a support by means of retaining members it is desirable to isolate the pressure pulses from the support. For example, this problem occurs in mounting brake lines on the body-in-white sheets of motor vehicles. Here, the transmission of pressure surges can cause vibrations in the audible range which can even be intensified by resonant bodies existing in the motor vehicle. Avoiding the transmission of the pressure surges onto the support from the lines is also called “acoustic isolation”.
DE 40 34 545 A1 has made known a two-piece retaining member of a plastic for holding at least one tubular component that has an outer cup of a hard material mountable on a support via a retaining area and an inner cup of a soft material inserted therein which has at least one bearing point to receive the tubular component. To prevent the transmission of vibrations onto a support via the tubular component, the inner cup is mounted on the outer cup via an anchoring device on either side of the bearing point and a continuous clearance exists between the inner cup and the outer cup in the area of the bearing point.
An annularly shaped inner cup can present a thickened area, which reduces the size of the insertion opening, on either side of the bearing point. This allows to tilt the tubular component into the respective bearing point and to hold it therein with ease. Further, a rib which is opposed to the insertion opening can be disposed at the inner circumference of the annular component so that the tubular component is supported only at some points in the bearing point of the inner cup made of a soft material, which also ensures advantageously that vibrations be damped. The ribs are of a compact cross-section.
The known retaining member still leaves a great deal to be desired with regard to the isolation of the pressure surges transmitted from the support via the lines.
Accordingly, it is the object of the invention to provide a retaining element of a plastic which enables the pressure surges transmitted via the lines to be isolated better from the support.
The object is achieved by a retaining element having the features of claim 1 . Advantageous aspects of the retaining element are indicated in the dependent claims.
The inventive retaining element of a plastic, which is useful for holding at least one line on a support, has
a basic body with a mounting area for mounting on the support and at least one retaining area with at least one line seating for at least one line, and a line seating which, at the inside, has a plurality of resilient ribs which project beyond the inside at different overhangs.
A line can be inserted into the line seating that is supported only on one or more ribs having a larger overhang beyond the inside of the line seating, but not on one or more ribs having a smaller overhang. The ribs having the larger overhang exhibit a smaller spring constant than does the basic body. Basic bodies which virtually are rigid are also incorporated. As a result, the transmission of pressure surges onto the basic body from the line will be reduced to a particularly large degree.
However, the ribs having the larger overhang are more sensitive to mechanical loads and exhibit a smaller self-centering action because of lower restoring forces than those of the ribs having a smaller overhang. Loads which could result in a damage to or destruction of the ribs having the larger overhang can occur, for example, while a line is pushed into the line seating or in operation by the effect of bumps or distortion. The ribs having the larger overhang are protected against such stresses by the fact that the line, when major deformations occur on the ribs having the larger overhang, additionally come to bear on ribs having the smaller overhang. In case of overload, it is primarily the ribs having the smaller overhang which will then absorb major forces. As a result, the ribs are protected from overload and a large restoring force is ensured. To this effect, the ribs having the smaller overhang preferably exhibit a spring constant which is at least as large or is larger than do the ribs having the larger overhang. The invention also incorporates the formation of the ribs having the smaller overhang at a spring constant which is so high that they nearly act like rigid stops.
Thus, this improves an acoustic isolation significantly in a normal operation while avoiding any damage to the ribs in case of an overload by large forces or transverse distortion, and ensures a high self-centering effect via large restoring forces. This also ensures that cases of distortion do not lead to a contact between the brake line and the rigid basic body, thus safely maintaining an excellent acoustic isolation.
The basic body and the ribs can be made of the same plastic material where different spring constants can be due to the configuration of the ribs and basic body. In an aspect, the line seating has a lining which is made of a non-rigid plastic material or rigid plastic material with a non-rigid elastic feature which, at the inside, has a plurality of resilient ribs which project beyond the inside at different overhangs. The different spring constants of the ribs and basic body can be owing here, at least partially, to the different plastic materials. In an aspect, the ribs are arranged at least partially in parallel. It is preferred to arrange all of the ribs in parallel. This has advantages in the manufacturing process.
In an aspect, the ribs are oriented in the axial direction of the line seating, i.e. in parallel with a conductor to be inserted in the line seating. In another aspect, the ribs are oriented in the circumferential direction of the line seating, i.e. around a conductor to be inserted in the line seating. For example, their progression is annular or in the form of a helix, and is possibly interrupted in the area of an insertion slot of the line seating.
In an aspect, ribs or sets of several ribs alternately project at a larger and a smaller overhang beyond the inside of the line seating or the lining, as seen in a circumferential direction or an axial direction of the line seating. This ensures that forces can be absorbed which are exerted by the line in different directions.
In an aspect, the ribs which project at the larger and the smaller overhangs are disposed at a uniform spacing across the inner circumference or in the axial direction of the line seating or the lining. This also favours the support of forces exerted by the line.
In an aspect, the line seating is formed in a substantially cylindrical, elastic cup having an insertion slot for the line. This makes it possible to install the line by simply pushing it into the insertion slot while elastically expanding the cup when it is safely seated in the elastically contracting cup.
In an aspect, the line seating or the lining has an axially oriented rib projecting at a larger overhang, on either side adjacent to the insertion slot. This favours the uniform support for an installed line at the circumference and counteracts its non-intended exiting from the insertion slot.
The measures below further improve such acoustic isolation while the ribs are protected against overload:
In an aspect, the ribs projecting at the larger overhang are of a width which is smaller than that of the ribs projecting at the smaller overhang.
Further, acoustic isolation is favoured by an aspect in which the overhang of the ribs projecting at the larger overhang is larger than the width of the ribs.
Further, acoustic isolation is favoured by an aspect in which the overhang of the ribs projecting at the smaller overhang is smaller than the width of the ribs.
The dimensional relationships of the ribs according to the foregoing aspects are particularly beneficial for ribs on a lining made of a non-rigid plastic material or rigid plastic material with a non-rigid elastic feature, e.g. a thermoplastic elastomer (TPE).
A great variety of rigid plastic materials can be chosen for the basic body. In an advantageous aspect, the lining is manufactured from a thermoplastic elastomer.
The mounting area can be mounted on the support in different ways. For this purpose, the mounting area can have a seating for or including a fixing bolt or rivet. In addition, the mounting area can be fixedly joined to a fixing bolt or rivet. The fixing bolt or rivet can be anchored in a seating of the support.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be described in more detail below with reference to the accompanying drawings of an embodiment. In the drawings:
FIG. 1 shows the retaining member in a perspective view oblique to the side to be placed against the support;
FIG. 2 shows the same retaining member in a perspective view oblique to the opposite side;
FIG. 3 shows some part of a retaining area in an enlarged side view;
FIG. 4 shows the same retaining member in a side view prior to being positioned on a welding bolt;
FIG. 5 shows the same retaining member while being positioned on a welding bolt in the same view;
FIG. 6 shows the same retaining member in one of the final mounting positions on the welding bolt in the same view.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The inventive retaining member 1 has a basic body 2 of a rigid plastic material. For example, this is a PA. (e.g. PA 6.6 or PA. 6).
The basic body 2 comprises a central mounting area 3 which is formed in a box shape or cage shape. A seating 4 for a fixing bolt is located in the mounting area 3 . The seating 4 is accessible through a hole 5 in that side of the mounting area 3 which faces the support. The seating 4 has disposed therein two groups of parallel lamellae 6 which are on two opposed sides and are inclined towards the hole 5 on either side.
Retaining areas 7 , 8 extend away from two opposed sides of the mounting area 3 . The areas comprise an approximately plate-shaped retaining arm 9 , 10 each which, starting from the two narrow sides, exhibit pocket-shaped cavities 11 , 12 , 13 , 14 . The retaining arms 9 , 10 extend from that side of the mounting area 3 which is to be placed against the support.
The arms each carry two clamping members 15 to 18 on the side to be faced away from the support. The members are designed as elastically expandable cups having an insertion slot 19 to 22 each. They house a line seating 23 to 26 each. The seating is confined by an additional clamping tongue 27 in the clamping member 18 .
Finally, at the side to be placed against the support, the mounting area 3 has a ring-shaped projection 28 , which extends around the hole 5 .
The aforementioned components of the retaining member 1 are made of a rigid plastic material. They may be advantageously injection-moulded in a single operation.
The clamping members 15 to 17 have linings 29 to 31 of a non-rigid plastic material. The linings 29 to 31 have ribs 32 to 34 which project each from their insides. The ribs extend in parallel with the insertion slots 19 to 21 and, hence, in parallel with the lines to be inserted. Several of them are disposed in sets over the inner circumference of the clamping members 15 to 17 .
Each lining 29 to 31 has two different sets of ribs 32 to 34 : ribs 32 ′ to 34 ′ projecting at a larger overhang a (than do the ribs 32 ″ to 34 ″) beyond the insides of the linings 29 to 31 and having a smaller width b (than have the ribs 32 ′ to 34 ′). It further has ribs 32 ″ to 34 ″ projecting at smaller overhang c (than do the ribs 32 ′ to 34 ′) beyond the insides of the linings 29 to 31 and having a larger width d (than have the ribs 32 ′ to 34 ′). This is illustrated in FIG. 3 by way of the clamping member 16 .
The clamping member 18 has no lining.
On diametrically opposed sides of the hole 5 and outside the ring-shaped projection 28 , the mounting area 3 carries rib-shaped contact members 36 , 37 on the side to be faced to the support. They extend slightly towards the two retaining arms 9 , 10 . They project at an overhang father beyond the side to be faced to the support than does the ring-shaped projection 28 . They are of a cambered design with their apex being approximately in the transverse central plane of the hole 5 and the overhang decreasing towards the retaining arms 9 , 10 . They together define a contact area 36 , 37 .
Two channels 38 to 41 are located on the two outer surfaces of the basic body between the contact members 36 , 37 and the linings 29 , 31 . Furthermore, the linings 29 and 30 are interconnected by channels 42 , 43 in the sides of the basic body 2 . The linings 29 , 31 and the contact members 36 , 37 are made of the same non-rigid plastic material. The channels 38 to 43 are also filled with this plastic material. Thus, all of the non-rigid components of the retaining member 1 can be injection-moulded in a single step.
The assembly and function of the retaining member 1 will be described below:
According to FIG. 4 , the retaining member 1 aligns the hole 5 onto a welding bolt 44 which is welded perpendicularly onto a sheet-like support 45 .
According to FIG. 5 , the retaining member 1 is pushed onto the welding bolt 44 . AS a result, the lamellae 6 will be slightly bent apart.
According to FIG. 6 , the retaining member 1 has seated its contact elements 36 , 37 on the support 45 at the end of assembly. The contact elements 36 , 37 are slightly compressed. The ring-shaped projection 28 is at a distance from the support 45 . The retaining arms 9 , 10 are at an even larger distance. The lamellae 6 prevent the retaining member 1 from slipping back from the welding bolt 44 or retain the retaining member 1 in place in a mounting position on the welding bolt 44 in a cooperation with a contoured area (e.g. a thread profile) on the welding bolt 44 .
Lines oriented perpendicularly to the plane of the drawing are pushed into the clamping members 15 to 18 through the insertion slots 19 to 22 . The clamping members 15 to 18 receive lines through which pressure surges are transmitted. The clamping member 18 is destined for the reception of a line through which no pressure surges pass.
The pressure surges are attenuated by the non-rigid linings 29 to 31 . To this effect, the lines are normally supported on the ribs 32 ′ to 34 ′. In case of particularly intense pressure surges or additional actions of force, the ribs 32 ′ to 34 ′ can be at least partially compressed in such a way that the lines come to bear on some portion of the ribs 32 ″ to 34 ″. They will then support the additional lines.
This achieves an acoustic isolation of the lines from the support 45 that has not been attained hitherto.
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A retaining member for holding and supporting an elongated element from a support includes a base portion and a holding portion. The base portion is attachable to the support. The holding portion is connected to the base portion and has a recess for holding the elongated element therein. The recess includes a tubular portion and a plurality of spaced ribs extending radially inwardly from the tubular portion to have different radial heights.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims benefit under 35 U.S.C. § 119(e) of U.S. provisional application Ser. No. 60/499,443, filed on Sep. 2, 2003.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a waste disposal apparatus and, more particularly, to an automated apparatus particularly suited for the sanitary and odorless disposal of waste such as soiled diapers.
2. Description of the Related Art
There are a number of systems for disposing of waste materials such as soiled diapers. The systems are often touted as a convenient way to dispose of such waste materials and reduce or eliminate any odor that may emanate from the materials. An example of such systems is U.S. Pat. No. 5,147,055 which discloses a diaper container that includes an activated charcoal filter to retain and absorb orders within the container.
Most waste receptacles are fitted with a lid designed to contain odors when the lid is closed. However, most lids are not designed to be perfectly air-tight in respect of their receptacles, or after repeated use become less-than air tight, permitting malodor to emanate from the receptacles even when they are closed. Even with the most air-tight containers, upon opening the container, the noxious odors escape into the area giving an extremely unpleasant sensation to the person attempting to add more trash to the receptacle. Location of the receptacles in a remote location is inconvenient and generally unsatisfactory.
Numerous receptacles have been proposed for temporarily holding diaper waste. These receptacles typically employ one of several approaches to reduce the emanation of malodor from the receptacle, which may be characterized as the use of making agents, odor sorbent material, inner lids or seals, air locks or sealed packaging.
Another problem with trash receptacles is that they tend to retain noxious odors even after the trash is ultimately removed. After a period of time a thorough and complete cleaning of such receptacles is necessary.
The scented diaper pail has been commercially available for many years. Scent is added to the diaper pail in the hope of hiding the smell of the malodor by producing a smell that masks the malodor to the olfactory senses. The problem with such pails is that the masking smell itself can often become irritating to the consumer, as well as the fact that most scented diaper pails loose their masking effect after a period of time.
A particularly difficult trash to retain for ultimate disposal is diapers. Diapers are typically stored and accumulated in a container. The cumulative odor of diapers being stored within the container frequently reaches such an offensive level that the diapers must be disposed of before the container is full. The latter leads to a large use of container liners such as bags, and excessive emptying operations. Excessive emptying operation can be of particular concern as one hesitates to leave the infant unattended or to carry the infant and the soiled diapers to a remote location. A further problem associated with such containers is that the containers themselves over time tend to retain the malodor even when no diapers are present in the containers. Therefore a thorough and complete cleaning of such containers is often necessary to reduce the lingering odor. Further, as many diaper disposal receptacles are not child-proof, toddlers playing around the container may inadvertently open the container to allow odors to escape or the child may reach in to touch solid diapers.
European patent application No. 0005660, the contents of which are incorporated by reference herein, describes a device for disposing kitchen refuse in packages enclosed by flexible tubing derived from a tubular pack of tubing surrounding a tubular guide. The device includes a tube sealing mechanism. The tubing passes from the pack over the top of and then down the guide to a position beneath the guide where it has been closed by fusion to provide a receptacle within the guide means. When this receptacle is full of refuse, a lever is manually operated to actuate an electro-mechanical apparatus including clamping and fusion devices that travel round closed tracks to perform the four-fold task of drawing the receptacle down below the tubular guide, fusing the tubing walls together to seal the top of the receptacle, sealing the tubing walls together to provide the closed base of the next receptacle and dividing the tubing by heat at a location between these two fusion locations to separate the filled package. There are a number of disadvantages with this device including the need for latches to prevent the wheels extending from the heating elements from inadvertently returning up the central track portions (as opposed to following the outer track portions as they should. A further disadvantage is that the heating element must be at least the width of the tube in order to seal the tube all the way across thereby preventing, for example, the escape of odors from the waste.
Another popular approach to disposing of such diapers has been with a device using a tube twisting mechanism to form a pouch about the diaper. As an example, see the disclosures of U.S. Pat. Nos. 4,869,049, 5,590,512, and 5,813,200, the contents of all of which are incorporated by reference herein.
The U.S. Pat. No. 5,813,200 to Jacoby, et al. discloses a device for disposing of soiled diapers in twisted packages. The device has a container body with a hinged base, a hinged lid, and an upward cylinder secured within the container body. A tubular core rests on a portion of the upward cylinder to allow rotation there between. A flexible tube or sleeve rests on a portion of the tubular core with the tubing being circumferentially pleated as stored. Springs are fixed to the container and project radially inward to engage a package formed from the tube. The springs are equally spaced around the interior of the container to hold the package during the forming of a twist in the tube.
The device disclosed in U.S. Pat. No. 5,813,200 is used to form a series of packages enclosing objects. The top of the flexible tubing is pulled upwards and tied into a knot. The closed end formed by the knot can then form the bottom of a package with the sidewalls formed by the tubing. The object is inserted and rests against the tubing near the knot. A rotatable interior lid is put into place and rotated such that the unused tubing and the tubular core rotate with respect to the package that is being formed. The package being formed does not rotate because it is held in place by friction between it and springs. Thus a package is formed between the knot and a first twist. Subsequently, objects are disposed and twisted in a like manner to form discrete packages with twists between them.
Devices such as that disclosed in U.S. Pat. No. 5,813,200 are a convenient way of disposing of soiled diapers. A disadvantage of the system is that the twists between packages may become unraveled, thereby allowing groups of diapers to collect within the tubing, which makes emptying the container more difficult. Further, the twists do not create a continuous, complete seal and, therefore, may allow odor to escape from a package. Increasing the twists between packages may eliminate the above disadvantages, however, this requires the use of additional tubing.
Another example of a device used to decrease odors that emanate from diaper waste is disclosed in U.S. Pat. Nos. 6,370,847 and 6,516,588, both issued to Jensen, et al. These related patents disclose a sealable diaper-disposal system that includes a container body, a tubular core on which flexible tubing is stored, and a tube-sealing mechanism having a pair of heating elements. The flexible tubing is pulled from the tubular core and passed between the pair of heating elements. The tube-sealing mechanism operates to move the pair of heating elements toward each other to fuse the width of the tubing, and away from each other to allow the tubing to be pushed into the lower portion of the container body.
The contents of all of the prior art references cited herein are incorporated by reference. From the above it can be understood by those having ordinary skill in the art that there are a number of disadvantages associated with prior art waste disposal devices using flexible tubing to form packets for disposal of waste materials. It is clear that a device is needed that will eliminate the disadvantages described above. Such a device should be relatively economical to purchase and operate, ensure that the seals between packets are complete and cannot come undone, and be easy to operate.
SUMMARY OF THE INVENTION
One aspect of the present invention is a waste container for sanitary disposal of waste including a container body defining a waste bin and an opening that provides access to the waste bin; a support mounted to the container body adjacent the opening, the support having a flange extending therefrom that is configured for mounting a tubing cassette above the waste bin, wherein the support encloses less than all of the opening to the waste compartment so that waste can be passed through the opening and into the waste chamber; a tubing cassette mounted to the flange of the support; and a tube twisting/sealing means for forming individual waste packets from tubing that is dispensed from the tubing cassette.
In another embodiment, the waste container comprises an automated turning or twisting mechanism, a rotatable tubing cassette which is structurally configured to be mounted to the flange of the support; and a retention means operationally configured to prevent rotation of a waste packet enclosed within the tubing when the cassette is rotated to allow twisting of the tubing to close the waste package. The flange may be configured to allow rotation of the tubing cassette. The cassette can be rotated by electrical power using a motorized rotating grip ring to create a closure by a twisting action of the flexible tubing when sequestering a waste packet. In one embodiment, the motorized apparatus for the sanitary disposal of waste comprises a plunging device with a suitable plate or disk for contacting the twisted closure of the waste package so that the plate or disk can downwardly push the enclosed package for a predetermined distance from the origin of tubing from the refill cassette's storage compartment, providing sufficient space for depositing a subsequent waste packet.
In another embodiment, the waste disposal device comprises an upper or head compartment located on top of the waste container, the upper or head compartment encompasses an apparatus comprising a drive plate mounted to the tubing cassette, a drive gear assembly engaged with the drive plate, and a motor mounted to the upper compartment apparatus and having an output shaft that rotates the drive gear when the motor is activated, the power from the motor being transmitted through the multiple gear assembly. A timing circuit may be employed for activating the motor to rotate the tubing cassette set at a predetermined amount of time or a predetermined number of times. A manually operated switch may be used for activating the motor.
In one aspect of the invention, the upper or head portion serves also as a lid over the lower receptacle compartment or waste bin of the waste container. The lid or upper compartment of the waste container of the invention can be hingedly attached to the container body for enclosing the opening to the waste bin. The lid or head portion of the container can be secured, for example, with a latch device. In addition, the hinge itself can include a latching mechanism or a biasing means to retain the lid in an open position. A foot pedal assembly can be attached to the lid as the mechanism for opening the lid. Such assemblies are well known to those of ordinary skill in the art.
In another aspect of the present invention, a waste container comprising a container body defining a waste bin and an opening that provides access to the waste bin is provided. The waste container further comprises a support mounted to the container body adjacent the opening, the support having a flange extending therefrom which is configured for mounting of a rotatable tubing cassette above the waste bin, wherein the support encloses less than all of the opening to the waste bin so that waste packs can be passed through the opening and into the waste bin.
In another aspect, the waste container is provided with a thrusting plate attached by a scissor slot assembly to a screw-type gear drive which is powered by an electrical motor through a gear transmission assembly; the activated thrust plate is extended downwardly to push a waste package into the bottom portion of the container after the package is sealed.
In one embodiment, the apparatus is further equipped with a plunging plate to effect a downward thrusting motion at the upper end sealed end of an enclosed waste package so that pulling of additional tubing from the refill cassette is effected so as to provide a pouch-like space below the cassette core opening in order to receive the next waste package, thereafter repeating the twist-tightening motion.
The invention also provides an automatically controlled apparatus for individually sequestering packs of odorous waste in a length of flexible tubing which is dispensed and depending from a core tube portion inside a tubular refill cassette. In one embodiment, the apparatus combines a lower compartment or bin for receiving and storing the tubing enclosed waste packs, and an upper compartment for accommodating and securing the electronically powered and controlled system for sequestering each pack of waste in the flexible tubing. In one embodiment, the sequestering or encapsulation of a waste package being initiated by an electrical actuator causing to start first, a rotational movement of the tubing refill cassette or dispenser so as to effect a twisting motion of the tubing in one direction while tightening of the flexible tubing which emanates from the cassette in a downward direction into the lower compartment or chamber of the waste receptacle. The waste packet sequestering part of the tubing is held by a retention or clamping device while the cassette is rotating. In a second step, the thrusting plate is activated to move downwardly in a thrusting motion to urge the sealed waste package into the waste receiving bin and simultaneously provide another length of flexible tubing for the next deposit of a waste packet. These and other aspects of the invention are disclosed in more detail herein below.
The waste disposal apparatus further provides a means for cutting the twisted sealed upper portion of the waste package and therefore the sealed flexible tubing. The cutting means are suitably located above the twisted portion of the tubing and below the refill cassette enabling removal of the sealed waste packages from the receptacle bins.
The sealing mechanism of the waste disposal apparatus can be further supplemented by an adhesive containing device or ribbon segmentally positioned on the inside surface of the tubing material, said adhesive being activated by the twisting of the flexible tubing. Alternatively, the flexible tubing material can comprise clinging properties for reinforced twist stabilization and sealing effect. The adhesive location can be placed on the inside of the flexible tubing at predetermined intervals or segments suitable for sequestering the waste packets.
A further aspect of the invention can be found in the film grip ring for gripping or holding the flexible tubing in place in order to prevent the inadvertent release of the stored refill tubing from the rotating cassette during the twisting operation. This advantageous aspect assists in creating a measurably effective tight twist lock of the sequestered waste packet in the tubing segment.
Another feature of the waste disposal apparatus comprises a trigger mechanism for actuating the thrust mechanism for determining the start of the downward motion of the thrusting plate at the end or completion of rotational motion the core tube effecting the twist closure of the flexible tubing above the sequestered waste packet. The trigger mechanism can be initiated by a timing device or optical counter which actuates the thrust mechanism after a preset interval. The optical counter can be aided by a laser-optical detection device.
In one embodiment, a receptacle is provided which comprises a container comprising a top portion, a bottom portion a side portion encompassing the void, a lid attached to the top portion of the container; a cassette comprising a rigid body formed by an internal core defining a first space, the core open at top and bottom, a surrounding casing wall positioned to provide a second space between the tubular core and the casing wall and a base wall joining a lower end of the surrounding casing wall to the lower end of the tubular core, a length of flexible tubing packed in the second space; one or more support member(s) projecting from the side portion of the container configured to retain the cassette between the top portion and the bottom portion of the container; and permitting communication of the flexible tubing from the cassette to the bottom portion of the container; a tube sealing mechanism operably configured to engage with the cassette to form and seal a packet of material in the flexible tubing by turning the cassette, and wherein the lid comprises an apparatus for actuating the tube sealing mechanism. In this embodiment of the invention, the receptacle can comprise, for example, a waste disposal container for disposing malodorous wastes including waste container for soiled diapers, nursing homes and hospitals wastes. The waste container comprises a support member, for example, a flange structurally configured to allow the cassette to be rotated thereon. In one embodiment, the cassette is mounted onto the flange and further comprises a drive plate, a drive gear structurally engaged with the drive plate, and a motor mounted on the container lid and having an output shaft that rotates the drive gear when the motor is activated. In another embodiment, the receptacle comprises a timing circuit activates the motor to rotate the cassette for a predetermined amount of time or a predetermined number of times. The receptacle may also comprise a manually operated switch for activating the motor. The receptacle comprises a lid which can be hingedly attached to the container, a plunging device which is movable downwardly into the bottom portion of the container for pushing a sealed waste package into the waste storage portion of the container. The receptacle may further comprise a first retention mechanism operably configured to prevent rotation of a packet when the cassette is rotated to create a seal in the flexible tubing; and a second retention mechanism operably configured to prevent release of the stored flexible tubing from the tubing cassette during rotation. In one embodiment, the receptacle may be further comprising a drive plate mounted on the cassette, a drive gear operably engaged with the drive plate, and a motor mounted to the container and having an output shaft that rotates the drive gear when the motor is activated. The receptacle may include a timing circuit activates the motor to rotate the cassette at a predetermined amount of time or a predetermined number of times.
In another embodiment, a receptacle is provided, comprising: a container comprising a top portion, a bottom portion, a side portion encompassing a void, a lid attached to the top portion of the container; a cassette comprising a rigid body formed by an internal core defining a first space, the core open at top and bottom, a surrounding casing wall positioned to provide a second space between the tubular core and the casing wall and a base wall joining a lower end of the surrounding casing wall to the lower end of the tubular core, a length of flexible tubing packed in the second space; one or more support member(s) projecting from the side portion of the container configured to retain the cassette between the top portion and the bottom portion of the container; and permitting communication of the flexible tubing from the cassette to the bottom portion of the container; a tube sealing mechanism operably configured to engage with the cassette to form and seal a packet of material in the flexible tubing by turning the cassette; a plunging mechanism operably configured to move a sealed waste packet downwardly while pulling a length of the flexible tubing from the cassette to create new space for enclosing a subsequent waste packet, and wherein the lid comprises an apparatus for actuating the tube sealing mechanism. In one embodiment, the receptacle may optionally further comprise a gripping mechanism for the flexible tubing to prevent release of the flexible tubing from the cassette during rotation of the cassette, or an apparatus operably configured to automatically package and seal waste material deposited within the flexible tubing into individual packets by means of motor-powered turning mechanism housed in the container, and wherein the flexible tubing is provided with an adhesive to reinforce the sealing mechanism.
In another embodiment, a method for disposing of waste material is provided, comprising: providing a length of flexible tubing having a first sealed portion of the tubing at a location along its length and an open end of the tubing; the tubing packed and stored within a disposable cassette and capable of retaining waste material therein; inserting the waste material through the open end of the flexible tubing until it contacts the first sealed portion of the tubing to form a waste package; retaining the waste package such that the waste package does not rotate in relation to the open end of the flexible tubing; rotating the open end of the flexible tubing to form a twist in the flexible tubing between the open end of the flexible tubing and the waste package; and optionally, sealing at least a portion of the flexible tubing to form a second sealed portion located above the waste packet enclosure. In one embodiment, the second sealed portion is accomplished by an electrothermal heating mechanism, or chemical adhesive application to at least a portion of the flexible tubing at the twist. In another embodiment, the retaining step of the method comprises retaining the waste package by gripping the waste package to prevent movement of the waste package during rotation of the cassette.
In yet another embodiment, a container for automated waste disposal, comprising: a container bin compartment structurally configured to received packaged waste material; a container top compartment enclosing an apparatus for automated packaging the waste material in the container bin compartment; a combination of an automatically controlled motor-driven cassette turning mechanism which packages the waste material into individual packets in a flexible tubing inside the container bin compartment; and an automatically controlled motor-driven plunging device operably configured to move a sealed packaged waste material and downwardly pushes the packaged waste material, thereby pulling a predetermined length of the flexible tubing to provide space for packaging of subsequent waste material.
The invention also provides a cassette for use with the receptacles of the invention. The cassette comprises an outer wall having a top surface, a bottom surface, and two side surfaces; an inner wall having a top surface, a bottom surface, and two side surfaces; flexible tubing positioned between the outer wall and the inner wall; a rim having a top surface and a bottom surface and two side surfaces positioned between the outer wall and the inner wall, the rim emanating from the top surface of either of the outer wall or inner wall and extending partially towards the other wall, the bottom surface of the rim facing the flexible tubing; wherein the rim comprises a plurality of protrusions or projections on the top surface of the rim. In one embodiments, the protrusions or projections are operably configured to engage with a rotation mechanism of a waste disposal device. In one embodiment, the cassette further comprises top and bottom surfaces which may optionally comprise protrusions, projections or a geared rim for engaging with a turning mechanism in making a sealed waste package.
BRIEF DESCRIPTION OF THE FIGURES
A more complete appreciation of the invention and the advantages thereof will be more readily apparent by reference to the detailed description of the preferred embodiments when considered in connection with the accompanying figures, wherein:
FIG. 1 is an elevational side view of an embodiment of the present invention;
FIG. 2 is a sectional side view thereof;
FIG. 3 is an elevational view of a refill cassette embodiment of the invention;
FIG. 4 is a sectional side view thereof;
FIG. 5 is an elevational view of an embodiment of the refill twister apparatus;
FIG. 6 is a sectional view thereof; and
FIG. 7 is a sectional view of the extended plunger mechanism embodiment.
It is notable that like items depicted in different figures may be referred to by the same reference numbers.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides an automatic device for the convenient and hygienic sequestering of waste packets. Waste packets are understood to comprise diapers or similar malodorous waste contents.
For the purpose of this invention, any device that closes off tubing at a point along the length of the tubing is considered a “tube-sealing means.” Therefore, for example, fusion devices, which close off tubing with heating elements, and twisting devices, which close off tubing by inducing a twist, are considered “tube-sealing means.” Several tube-sealing means are disclosed herein above in the background of the invention. Other tube-sealing means are disclosed in U.S. Pat. Nos. 6,128,890 and 6,065,272, and U.S. Publication No. US 2002/0162304, the contents of all of which are incorporated by reference herein. In this description and the accompanying figures of the automated sequestering and waste disposal apparatus, reference is only made to a flexible tubing-twisting or twist-locking mechanism for closing off the flexible tubing to sequester the individual waste packets within the tubing as well as the associated downward placing of the sequestered waste packets by a plunger device.
The present invention as described in this embodiment is an improvement over other waste disposal devices or systems in that it comprises an automatically controlled mechanism for sequestering the waste packets individually inside a flexible tubing bay of some length dispensed from a refillable cassette. The hands-off embodiment features a motor-driven rotation of the refillable cassette comprising an inner core of dispensable tubing. When the waste device is actuated, the rotational movement of the cassette effects the twisting of the tubing so as to form a sealed waste packet while the packet is held in place by spring-aided holder/brackets. One embodiment comprises a driveshaft connected to the motor through a gear assembly or transmission. The driveshaft is activated when rotational movement of the cassette is completed and the waste packet is closed off or sequestered in the tubing material. In this embodiment, the driveshaft, for example, is connected by a pinion through the connecting scissor slots to the thrust plate of the plunger. The rotation of the driveshaft, i.e., a rod with a screw-type outer ridge, winds through the nut-like center hole of the pinion, which is thereby slideably moved along holding or locating means or rod causing the scissor connectors to extend and vertically move the thrust plate to plunge or press downwardly on the sealed waste packet, which is consequently placed in the receptacle portion of the waste container.
The motorized two-step mechanism of the apparatus controlling the twisting and plunging of the automated waste sequestering operation can be manually turned on by pushing a button, for example, on the top portion of the container, lid or head portion of the container. Alternatively, the mechanism may be controlled by a foot operated switch or lever. The motorized system is activated by pressing the button, and the button makes electrical contact with the actuator of the motor in the apparatus causing an initial twisting rotation of the cassette core tube. The rotational movement of the cassette by the motor driveshaft being transmitted through a set of gears to the rotational ring that engages the cassette rim through the small ridges projecting therefrom on top of the cassette when the attached upper head or lid compartment of the waste receptacle is closed.
The second step of the automated control of the waste sequestering mechanism causes a plunging device to downwardly thrust and extend so that the sealed waste package is pushed into the receptacle space of the bottom portion of the container. Thus, the flexible tubing is pulled from the storage compartment of the cassette through a gap between the inner core tube and the rim atop the refill cassette to form a new space for depositing new waste.
Alternatively, the lid can be operationally configured to be opened by foot. In this embodiment, the waste disposal device is provided with a pedal-like structure which is operably configured and attached to the lid so that the motorized mechanism can be operated or activate by the closing of the lid. A waste load is deposited into the open center of the cassette. Upon release of foot-operated mechanism, the lid closes and the motorized actuator mechanism is activated, for example, using a cog gearing system which causes rotation of the cassette holding a tubing bag receptacle. The rotation accomplishes two activities for sequestering a diaper or similar waste load and dropping or moving the same downwardly into the tubing bag and into the container bin.
In the closed lid position, the actuator initiates the rotational force on the tubing cassette by the refill twister exerting pressure on the beveled ring surface of the cassette. The rotational movement is measured to continue until sufficiently tight twisting has been effected on the tubing containing the waste so as to seal the top opening and thereby retain the waste load. At the moment when the twisting or tightening by cassette rotation is complete for sufficient closure of the tubing tubular bag, a vertically dispensed gearing mechanism is turned on and causes a downward movement of the cassette holder and cassette with attached waste loaded tubular receptacle portion. This downward thrust is mediated through a scissor link assembly which stretches out to extend along the axis of the cassette opening, moving the sequestered waste load downward.
Simultaneous to the motorized rotational force input on the cassette rim, a film grip ring is activated to contact and clamp down on to the flexible tubing emanating and hanging over the top edge of the inner core tube of the tubing cassette. This contact prevents release of tubing from the storage compartment of the cassette during the rotational twisting operation.
Throughout this specification, the word “comprise” or variations such as “comprises” or “comprising” will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers. The general embodiment of the present invention is best understood by reference to FIGS. 1-7 of the drawings.
Referring to FIG. 1 , a waste container 10 is shown comprising a lower or waste storing bin compartment 15 and an upper lid or head compartment 20 with an optional activation start button 5 .
The automated twist waste disposal apparatus useful for sequestering waste packets such as diapers in twist-sealable flexible tubing as illustrated in one embodiment of the invention by taking reference to FIGS. 1 , 2 , 3 , and 4 .
The disposal device 10 comprises top or lid portion 20 which comprises hingedly attached and latch-secured pivoting lid or cover configuration and a bottom or bin portion 15 , comprising an approximately cylindrical or cone-like shape.
In FIG. 2 , the lid portion 20 is shown to contain an apparatus for automatic control of twisting and lowering of tubing below the refill cassette, the apparatus comprising an upper body portion 21 and a lower body portion 22 . More specifically, the lid 20 houses or contains the apparatus upper body 21 , comprising an electronic motor-driven control gear assembly 110 , an actuator 45 , a rotatory grip ring or refill twister 35 for contacting and rotating the tubing refill cassette body 50 effectively twisting the flexible tubing 52 which emanates through a gap 54 between the rim 57 of the cassette 50 and the core tube 61 , and is folded down through the open cassette tube core area 51 into the interior bin space 16 as partially shown in FIGS. 3 and 4 .
The lower body of apparatus 22 encompasses the removable refill cassette 50 as well as a retaining means or spring assembly 55 positioned to hold the flexible tubing 52 which encloses a waste pack (not shown) in the bin space 16 during the twist-closure operation. The tubing cassette 50 houses a length of tubing material 52 for sequestering the waste packets sequentially in the waste bin space 16 .
A lid 20 secured by a hinge 81 to the waste bin 15 includes a latch 82 . The waste bin 16 also includes a hinged base 19 for providing access to the lower interior of the second waste bin 16 . The hinged base 19 includes a latch (not shown) for securing the hinged base 19 in a closed position.
The bottom rim 58 of the tubing refill cassette body 50 rests on a flange support or holding ring 70 which is affixed to the internal wall side of the bin 15 of the device 10 . The flexible tubing material 52 is stored in a continuously folded manner in the tubing storage compartment 59 of the cassette 50 .
Referring to FIG. 5 , the apparatus embodiment of the gear assembly 110 in a housing or cap structure 155 of the upper body portion 21 of the electronic motor-driving apparatus 30 has a motor 47 located near the gear idler 25 , which motor 47 is started when the manually depressed button 5 on the lid 15 makes contact with the switch 95 . The first action of the motor-driven gear assembly causes rotation of the refill twister 34 comprising a tubular ring structure 36 which exhibits a notched bottom surface 130 that is situated to make contact with the top ring or collar of the refill cassette 50 so as to propel the cassette into rotational motion. The tubular refill twisting device 36 is provided with a ridge 150 .
Referring to FIGS. 6 and 7 , an embodiment of the invention is represented showing the scissor link assembly 210 linked a slideable U-joint type linkage 215 . The pinion is saddled on a radially positioned carrier device 36 with a bracket 225 while at one point attached to a linkage 210 connecting assembly holder 215 , and at another point attached to a drive rod 235 . The drive rod 235 comprising a screw-like wound surface is inserted into the nut-type center of the which can be centrally moved along the carrying means or rod 36 by the revolutions of the screw-type positioning rod so that the drive rod 235 rotations cause the scissor link connecting linkage 215 to move towards the center so as to move the plunger plate 40 vertically downward through open central portion 37 of the upper apparatus configuration 21 and the cassette core opening 62 .
The twisting operation is further facilitated by the film grip ring 35 which, during the twisting operation, acts as a brake pressing onto the flexible tubing 52 atop the cassette core tube 61 , and prevents the tubing 52 from being pulled out of the refill cassette 50 storage compartment 60 during the cassette rotation.
A revolution counting mechanism is included in the upper portion of the apparatus 21 controlling the twisting operation as well as the downward motion of the plunger 40 .
Referring again to the illustrations of FIGS. 3 and 4 , the refill cassette 50 stores the flexible tubing 52 which emanates from the storage compartment 59 through the gap 54 between the rim 57 and the cassette's core tube wall 61 and then fords into the inner core area 62 , hanging into the bin space 16 below. The rim 57 is provided with small ridges for effectively engaging the refill twister 34 , in particular, the gear surface the refill twister 130 when rotating the cassette 50 and the top portion of the flexible tubing enclosing the diaper deposit (not shown). An exemplary tubing cassette is disclosed in U.S. Pat. No. 4,934,529, the contents of which are incorporated by reference herein.
Taking reference again to FIG. 2 , the lid portion 20 of this embodiment 10 can be opened by depressing a foot pedal arrangement 65 which acts through a push rod 66 on the hinge assembly 81 of the lid 20 , exposing the open core area 62 of the refill cassette 50 for depositing a waste packet.
As further illustrated in FIG. 2 , the retention springs 55 are attached to the flange 70 and retain or hold a waste package (not shown) stationary while the rotating refill twister 34 causes the cassette collar or rim 57 to rotate the tubing cassette 50 inducing a twisting motion in the flexible tubing 52 . As used herein, the term “retention means” shall include any retention device for retaining or restraining a waste package (not shown) in a stationary position while the cassette 50 and the flexible tubing 56 dependent through the cassette core tube area 62 is rotated. The term shall include, for example, retention devices as disclosed in U.S. Pat. Nos. 4,869,049, 5,590,512, 6,170,240, 6,128,890, 6,370,847, JP 592039015 (P2000-247401 A), and U.S. patent Publication No. US 2002/0162304, the contents of all of which are incorporated by reference herein. Other means for rotating the tubing cassette 50 may be employed.
As used herein, the term “retention means” shall include any retention device for retaining a tubing enclosed waste package stationary while the flexible tubing 52 is rotated. The term shall include, for example, retention devices as disclosed in U.S. Pat. Nos. 4,869,049, 5,590,512, 6,170,240, 6,128,890, 6,370,847, JP 592039015 (P2000-247401 A), and U.S. patent Publication No. US 2002/0162304, the contents of all of which are incorporated by reference herein.
Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made therein without departing from the spirit and scope of the invention as defined by the appended claims. For example, components in one figure can be combined with components shown in another figure.
STATEMENT REGARDING PREFERRED EMBODIMENTS
While the invention has been described with respect to preferred embodiments, those skilled in the art will readily appreciate that various changes and/or modifications can be made to the invention without departing from the spirit or scope of the invention as defined by the appended claims. All documents cited herein are incorporated in their entirety herein.
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A waste disposal receptacle is provided with an apparatus for sanitarily disposing of solid waste material such as diapers, hospital and nursing home waste products, and biologically hazardous wastes. The receptacle houses an automated mechanism for sealing and packaging the waste material and includes a container, a motorized turning device and a cassette containing a storage of flexible tubing for packaging the waste material.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a divisional application of application Ser. No. 08/399,078, filed Mar. 8, 1995, entitled APPARATUS AND METHOD FOR IMPARTING WRINKLE-RESISTANT PROPERTIES TO GARMENTS AND OTHER ARTICLES, now U.S. Pat. No. 5,749,163, issued May 12, 1998, the disclosure of which is incorporated herein by reference.
TECHNICAL FIELD OF THE INVENTION
The field of the invention is that of wrinkle-resistant garments and more particularly a novel apparatus and method of manufacturing wrinkle-resistant garments.
BACKGROUND OF THE INVENTION
Wrinkle-resistant fabrics and methods of imparting wrinkle resistance to cotton and cotton-blend fabrics are well known in the textile industry and have been used to manufacture wrinkle-resistant or permanent press garments. Typically, wrinkle-resistant fabrics are produced by applying to or otherwise impregnating a fabric with resins or other crosslinking agents and, in the presence of a catalyst, heating the fabric to a temperature at which cross-linking of the reactive fibers, i.e. curing, will occur at the desired rate. Several examples of durable press compositions and processes are discussed below.
U.S. Pat. No. 4,336,023 to Warburton, Jr. discloses a process for treating a fabric for the purpose of rendering the fabric wrinkle-resistant. The disclosed process includes the steps of saturating the fabric with a durable press treatment solution containing an activated bis-vinyl compound, a copolymer, and an aqueous base; passing the fabric through pad rolls; drying the fabric; and curing the fabric.
U.S. Pat. No. 4,623,356 to Hendrix discloses a process to prevent yellowing of durable press fabrics which have been treated with a non-formaldehyde finishing agent such as glyoxal, polymers of glyoxal and higher aldehydes. This process includes exposing a moist finished fabric to an oxidation solution at an elevated temperature, followed by neutralization, rinsing and drying operations. The oxidative treatment may be performed either during or immediately after curing of the finished fabric in a continuous process, or at a later time as a totally separate process.
U.S. Pat. No. 3,488,701 to Herbes discloses a crease-proofing composition comprising certain imidazolidinones. The crease proofing composition of the Herbes patent is applied to cellulosic textile materials. A catalyst or accelerator may also be employed. Following the application of the crease proofing agent and curing catalyst, the material is subjected to drying and curing operations.
U.S. Pat. No. 4,323,624 to Hunsucker discloses using certain urea-aldehyde compositions to treat textiles and nonwoven cellulose products so as to impart wrinkle resistance and durable press properties. Hunsucker further discloses that catalysts such as magnesium chloride and zinc nitrate may also be used. The cellulosic materials are saturated with the composition, pressed and then heated to cure the resin. Hunsucker discloses that the treated fabrics have much improved hand when the treatment is conducted in the presence of nitroalkanes or nitroalkanols, and the residual aldehyde is much reduced, thereby improving the environment.
U.S. Pat. No. 3,656,246 to Lord discloses a method of making a durable press garment which may be conducted in the home. This method includes the steps of pressing an assembled garment to form at least one crease therein, impregnating the garment with a liquid, containing a crease proofing agent, permitting the garment to dry and then heating the garment to cure the crease proofing agent. Lord further discloses that the method may also include the initial fabrication of the garment by cutting and sewing together suitable pieces of fabric and/or repressing the garment after the drying step and before the curing operation.
Other examples of durable press agents and processes are disclosed in U.S. Pat. No. 3,632,296 to Pandell and U.S. Pat. No. 3,181,927 to Roth and in copending patent application Ser. No. 08/078,608.
While known methods of manufacturing durable press garments generally result in garments having satisfactory permanent press or wrinkle-resistant properties, these methods require the use of excess resins which add to the cost of manufacture and pollute the environment and, in most cases, produce garments which exhibit undesirable hand (i.e. excessive stiffness).
The present invention provides a method and apparatus which eliminate the use of excess durable press resins and other chemicals and which yield wrinkle-resistant garments having excellent hand (i.e., softness).
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention, an apparatus for use in the manufacture of wrinkle-resistant garments comprises a housing enclosing a drum which is rotatable on a generally horizontal axis, whereby when the drum is rotated with garments disposed therein a tunnel defined by the garments is formed. Hingedly secured to the housing is a door. A blower and a heating element are arranged to provide heated airflow from the top of the apparatus through the drum in a vertically downward direction. A vent located below the drum is provided for the exhaustion of the heated air. Known commercial tumble dryers may be used for this aspect of the invention. Mounted on the door, exterior to the housing and drum when the door is in a closed position, is an atomizer unit positioned to discharge a durable press resin in the form of a mist through a hole in the door and into the garment tunnel when the door is closed. Preferably, the apparatus includes a dampener or other means for controlling the exhaustion of air in order to achieve a more uniform wetting of the garments with durable press resin. In practice, durable press resin is fed into the atomizer unit while the garments are being tumbled until the garments are sufficiently wetted with the resin. The wetted garments are then ready for curing to impart wrinkle-resistant properties to the garments.
In another embodiment of the present invention a programmable controller is used for controlling the dampener, the blower and the heating element. Further, a second atomizer unit may also be used and mounted to the door to improve the efficiency of the apparatus.
In a particular embodiment of the method of the present invention, a durable press garment is manufactured by inserting garments constructed of a cellulose fiber-containing fabric (such as cotton) into an apparatus capable of tumbling the garments in such a manner as form a tunnel defined by the garments. While the garments are being tumbled a durable press resin is injected into the tunnel in the form of a mist, impregnating (i.e., wetting) the garments with durable press resin. The wetted garments are then dried and cured, resulting in a wrinkle-resistant garment. Further, prior to curing, the garments may be pressed to impart creases and shape to the garments as is often desired.
These an other aspects of the present invention are described with greater specificity in the following detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete description of the present invention and the advantages thereof, reference is now made to the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a front perspective view of a modified tumbler/dryer apparatus embodying features of the present invention,
FIG. 2 is a rear perspective view of a modified tumbler/dryer apparatus embodying features of the present invention,
FIG. 3 is a detailed view of the dampener system of the present invention,
FIG. 4 depicts aspects of the present invention in operation, and
FIG. 5 is a front perspective view of an alternative embodiment of the present invention.
DETAILED DESCRIPTION
In accordance with the subject invention, a novel apparatus and process is provided for producing garments having wrinkle-resistant properties and excellent hand.
In the exemplary embodiment of the invention, as disclosed in FIGS. 1-4, a commercial tumble dryer generally designated 10 is shown to comprise an external housing 12, within which is mounted a tumbling drum 14 having a forward access opening 16. The tumbling drum 14 may be mounted in any usual or preferred manner to be driven rotatably by suitable power means, most typically an electric motor and control circuitry well known in the construction of commercial tumble dryers. A preferred commercial dryer is the Huebsch Model JT120FG 120 lb. capacity commercial dryer. Hingedly mounted on the front of the dryer housing 12 is.--an access door 18.
During the operation of the dryer 10, a blower (not shown) causes air to be circulated into the tumbling drum 14 through upper portion of the dryer. Suitable air heating means (not shown) are also provided such as those heating means typically included on commercial dryers, including the preferred dryer identified above, all well known in the art. Referring to FIGS. 1 and 2, provided at the bottom of the dryer and in communication with the interior of the tumbling drum 14 is a lower vent opening 20 through which the circulated air is vented from the tumbling drum 14. The vented air is exhausted exteriorly of the tumbling drum through suitable duct means 22. This construction which circulates air from the top of the dryer and vents through the bottom of the drying apparatus has been found to be particularly suitable for most efficiently wetting garments with durable press resins and other chemicals. This vertically downward airflow configuration is typical with commercial dryers. In contrast, in a typical noncommercial home dryer, air is circulated from the rear or back wall of the drum.
Referring to FIGS. 2 and 3, disposed within the exhaust duct means 22 is a dampener 26 to control the flow of air through the tumbling drum 14. The dampener 26 is pneumatically controlled through a programmable controller 28 which is operably connected to the dryer circuitry. A more detailed illustration of the dampener system is provided in FIG. 3.
Referring to FIG. 3, an electronically controlled valve 30 receives signals from the controller 28 (FIG. 2), opening and closing air ports A and B in the valve 30. More particularly, an electronic signal from the controller 28 will energize a solenoid (not shown) in valve 30, allowing air to be supplied by a suitable pressurized air source (not shown) through port B and conduit 32. The air flow from open port B causes air cylinder piston 34, which is operably connected to dampener control arm 36, to move the dampener control arm 36 downwardly, thereby closing the dampener 26. As the control arm 36 and piston 34 move downwardly air is exhausted from the cylinder 38 through conduit 40, which is attached to port A. Conversely, the dampener 26 is moved to the open position, allowing air to flow through the drum and to be exhausted, by removing the electronic signal from the solenoid valve 30, thereby causing air to be supplied through port A. Air supplied through port A and conduit 40 into cylinder 38 moves the piston 34 and arm 36 upwardly, moving the dampener 26 to an open position. Preferably an adjustable stop collar 42 is provided on the air cylinder piston 34 allowing the dampener position to be better controlled. The dampener 26 is adjustable from full open (i.e., maximum exhaust flow) to full close (i.e., no exhaust flow). The use of a dampener (or other suitable means to control the exhaustion of air from the drum) is a significant component of the apparatus, since it has been found that without the dampener (i.e., exhaust fully open) the durable press resin was unevenly distributed on the garments.
In the preferred embodiment of the invention the programmable controller 28, identified by numeral 28 in FIG. 2, may also control all original dryer functions provided on typical commercial dryers, such as heat settings, cycle times, reversing and non-reversing tumbler rotation and air only/cool down cycles. Added functions, both pneumatic and electric, can also be controlled by the controller, such as dampener control, safety circuits, chemical level sensors, and atomizer control. A suitable programmable controller is an Omron Sysmac C28K programmable controller.
In the exemplary embodiment of the invention the tumbling drum 14 is rotating in a clockwise direction as shown in FIG. 4. As shown, the garments to be treated are carried adjacent to the drum 14 until they reach approximately the 10 o'clock position and then fall away from the surface of the tumbling drum 14, descending toward the lower right quadrant of the drum. Thus, when a sufficient amount of garments are loaded into the tumbling drum and the drum is rotated, the garments form a tunnel or cavity 44, i.e., a vortex, as shown in FIG. 4. The formation of this tunnel 44 has been found to be significant in obtaining the most effective treatment and wetting of the garments with durable press resins.
Thus, for optimum performance, it is necessary that there are enough garments to create a "tunneling" effect but not too many garments so as to fold the tunnel. It has been found that the modified Huebsch commercial dryer described above having a 120 lb. capacity and revolving at about 30 revolutions per minute provides an extremely suitable tumbling apparatus. For example, 75 to 110 pounds of dry garments placed in such commercial apparatus will provide a suitable tunnel into which the durable press resin can be injected.
Referring again to FIG. 1, garment access door 18 includes a window 46. Preferably, the original glass window on the Huebsch JT120FG is replaced with a window made of a Lexan material approximately 3/16" thick. Attached to the garment access door window 46 is a support bracket 48 for mounting an atomizer unit 50. The bracket 48 may be attached by any means. For example, holes may be drilled into the access door window 46 to accept the atomizer support bracket 48. The atomizer unit 50 is attached to the door 18 of the tumbling apparatus 10, and is in communication with the interior of the tumbling drum 14. For the purpose of this disclosure, the phrase atomizer unit is defined broadly as a device capable of projecting a liquid in the form of a mist or fine spray. Off the shelf atomizer units are generally suitable and are readily available and well known. A preferred atomizer unit is the Flowtron Model No. MS10OB10-Mister Electric Bug Sprayer.
The atomizer unit 50 injects chemicals (i.e., durable press resins used to impart wrinkle-resistant properties to garments or other articles) through nozzle 52 into the tumbling drum 14 through a hole in the garment access door window 46. An access hole measuring 3A" in diameter should be suitable. The access hole and atomizer unit 50 are preferably positioned off center and to the left side of the door in order to inject the durable press resins into the tunnel formed by the tumbling garments, as shown in FIG. 1. Most preferably, the atomizer unit 50 is positioned such that chemicals are injected toward the lower left, rearward portion of the garment tunnel when the garments are tumbled in a clockwise direction, as shown in FIG. 4. It has been found that by targeting the lower left portion of the tunnel substantially all of the chemical resin is absorbed by the garments and the walls of the tumbler remain substantially dry.
It is believed that when the chemical resin is injected into the garment tunnel the pressure in the tunnel is higher than the pressure adjacent the exhaust vent 20 at the bottom of the dryer 10. It is believed that this pressure differential causes the resin to flow from the inside of the tunnel through the garments toward the low pressure area adjacent the exhaust vent 20. This high pressure-low pressure flow pattern is believed to result in improved wetting by removing the air trapped in the garment and replacing it with chemical. Further, this process is particularly effective with cotton fibers which are hollow and porous, since the pressure differential is believed to result in the removal of air within the hollow cotton fibers and the replacement of such air with durable press resin, thereby resulting in more thorough wetting of the garments and enhanced wrinkle-resistant properties.
Referring to FIGS. 1 and 2, the exemplary embodiment the present invention also includes an external power switch box 54 which includes replaceable in-line fuses to protect against voltage overloads, as well as an emergency on-off switch. The external power switch box 54 also allows the apparatus to be portable within the production facility. Also, mounted to the tumbling apparatus is a manually controlled 120 volt electric outlet 56 for controlling the required voltage to the atomizer unit 50.
A support bracket 58 is mounted on the top of the modified dryer 10 for attaching a main chemical storage tank 60 to the apparatus. In the exemplary embodiment (FIG. 1) the main chemical storage tank 60 has capacity of 10 gallons. Attached to the main chemical storage tank 60 is pipe 62 or other suitable conduit which runs to a mix/measure chemical storage tank 64. In the exemplary embodiment (FIG. 1) the pipe or conduit 62 attaches to the mix/measure chemical storage tank 64 on the top or inlet side 66 of the mix/measure chemical storage tank 64.
The mix/measure chemical storage tank 64 preferably should have sufficient capacity for operating the apparatus for at least a single load, which in the exemplary embodiment described herein equates to about 5-8 minutes operating time. The mix/measure chemical storage tank 64 is attached to the housing 12 by a support bracket 68 preferably mounted on the front side of the housing 12, above the garment access door 18 next to the manually controlled 120 volt outlet 56. In communication with and connected to the bottom of the mix/measure chemical storage tank 64 is tubing 70 connected to the atomizer or misting unit 50 for transferring chemicals to the atomizer unit 50.
Mounted in-line between the main chemical storage tank 60 and the mix/measure storage tank 64 is a manual control ball valve 72 for controlling the flow of chemical between the main chemical storage tank 60 and the mix/measure chemical tank 64. A second manual control ball valve 74 is mounted in line between the mix/measure chemical tank 64 and the atomizer unit 50 for controlling the flow of chemicals therebetween.
The apparatus further includes a process control switch 76 enabling the operator to change from one program to another stored in the program controller 28. In the preferred embodiment, the process control switch 76 allows the operator to change between chemical wetting operations and standard dryer operations.
Referring to FIG. 5, there is shown an alternative embodiment of the present invention wherein two atomizer units 50 and 50A are mounted to the access door window 46. The construction of this alternative embodiment is essentially the same as that shown in FIGS. 1-4 except that a second conduit 70A is incorporated to permit flow of resins and other liquids from mix/measure tank 64 to atomizer unit 50A. Additionally, a second manual control ball valve 74A is connected to conduit 70A to control liquid flow to atomizer unit 50A. Also shown in FIG. 5 are noise suppressors 78 connected to atomizer units 50 and 50A at the air inlets thereof. The noise suppressors 78 shown each comprise a 211 PVC elbows So having attached thereto a portion of common flexible electrical conduit 82. The inclusion of a second atomizer unit increases the efficiency of the apparatus by decreasing the amount of time needed to completely wet the garments with resin, while still obtaining maximum utilization of the resin.
The operation of the above-described apparatuses in the manufacture of wrinkle-resistant garments is as follows. Garments or other articles constructed of a cellulose fiber-containing fabric, such as cotton or a cotton-blend garment, are placed into the tumbling drum 14 through access door 18. The door 18 is closed and the tumbling operation is commenced by selecting the proper control commands via the programmable controller. In the operation shown in FIG. 4 the drum is rotating in a clockwise direction and the garments form a tunnel or cavity 44.
While the garments are being tumbled, a durable press resin or agent is fed into the atomizer unit 50 through the mix/measure storage tank 64 and injected into the tumbling drum 14 in the form of a mist. For the purposes of this disclosure, the phrase durable press resin is intended to include any suitable resin, agent or other chemical or chemical compound which imparts wrinkle-resistant properties to fabrics. Suitable durable press resins are well known in the industry and the subject process and apparatus is not limited by the type of durable press resin used. For example, satisfactory results have been achieved using durable press resins produced and sold by Highpoint Chemical Company.
The tumbling and resin injection process is continued until the garments are completely impregnated with resin. Preferably, no excess resin is injected. For example, with the modified Huebsch dryer described above, it has been found that approximately 50 pairs of pants (75 to 110 lbs.) will be 100% wetted by injecting 31/2 gallons of resin and tumbling for 15 minutes, without any excess resin accumulating in the tumbling apparatus.
After the garments have been wetted in the subject apparatus, the garments are dried to about 10% moisture by switching the apparatus to the standard drying operation and tumble drying the garments for approximately 20 minutes at 140° F. The garments are then pressed to impart the desired creases and shape to the garment. Pressing the garments at 310° F. for 5 to 30 seconds has been found to be suitable. Next, the garment is placed in a curing oven to cure the resin and thereby impart wrinkle-resistant properties to the garment. Depending on the weight of the garments and the type of fabric, curing temperatures typically range from 280° F. to 310° F. and curing times from 5 to 15 minutes.
Various modifications to and uses of the present apparatus and method have been recognized. For example, various additional treatment fluids may be used in the present invention to get the desired end product, such as denim wash components, softeners and other compounds well known in the art. One "denim wash" compound which has been used in connection with the apparatus disclosed herein and has resulted in the desired garment characteristics is Virco Quickstone 50 manufactured by the Virkler Company. Similar results have been achieved using the present apparatus without the use of enzyme treatments by heating the durable press resin to about 130° F. prior to injection into the drum. To maintain the 130° F. temperature of the durable-press resin, the main chemical storage tank can be insulated.
Although the present invention has been illustrated in the accompanying drawings and described in the foregoing detailed description in terms of certain exemplary and preferred alternative embodiments, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the invention.
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A method of manufacturing durable press garments by inserting garments constructed of a cellulose fiber-containing fabric into an apparatus capable of tumbling the garments about a generally horizontal axis in such a manner as form a tunnel defined by the garments. The method tumbles the garments and injects a durable press resin into the tunnel in the form of a mist to impregnate the garments with the durable press resin. The method dries the impregnated garments and cures the dried garments.
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BACKGROUND OF THE INVENTION
This invention relates to an improved process for preparing lignosulfonate additives for drilling fluids used in the drilling of oil and gas wells. The invention also relates to drilling mud additives which comprise a mixture of zirconium and titanium lignosulfonates which are substantially free of chromium.
U.S. Pat. No. 4,220,585 to Paul H. Javora and Bethel Q. Green, incorporated herein by reference, describes chromium-free drilling fluid additives effective as viscosity controlling agents. The additives are composed of complex lignosulfonates containing titanium and/or zirconium. The additives are stated to be, in many cases, more effective viscosity controlling agents than the chromium or chromium-iron lignosulfonates which are widely used in the drilling industry. The additives have the additional advantage of avoiding the toxic nature ascribed to chromium lignosulfonates.
Lignosulfonates, in accordance with U.S. Pat. No. 4,220,585, are prepared by reacting lignin liquors obtained from pulping wood with salts of the desired metal or metals. When necessary, the precipitated material can be removed. Oxidation of the material, which modifies certain properties such as the thinning or reduction of the viscosity of clay suspensions and reduction of the gel-like properties of such suspensions, can be any one of the process steps.
In the commercial preparation of the drilling fluid additives of U.S. Pat. No. 4,220,585, normally, the lignosulfonate is purchased as the calcium salt. Most of the calcium must be removed, because calcium adversely affects the viscosity control properties of the final product. A metal sulfate is added to precipitate the calcium as calcium sulfate and to form metal lignosulfonates. Typically, the calcium sulfate is removed by filtration. The added metal sulfate may be in the form of zirconium sulfate and/or titanium sulfate. Sulfuric acid may also be added to aid in precipitating the calcium sulfate.
Because of the chemically complex nature of the sulfonated lignin material prepared in accordance with U.S. Pat. No. 4,200,585, their exact chemical composition is not readily ascertainable. Consequently, reference to these compositions as "lignosulfonates" does not imply a limitation to salts formed by base-exchange chemical reactions. They may also include chelates as well as other metal complexes.
When making drilling fluid additives according to U.S. Pat. No. 4,220,585, it has been found that the filtration rate drops to zero because of total blinding or plugging of the filter cloth. Further processing of the lignosulfonate solution becomes impractical. Even with continuous cleaning of the filter cloth, only limited production is achieved. Consequently, production of these chromium-free lignosulfonate drilling fluid additives is inefficient and unduly expensive.
U.S. Pat. No. 3,544,460, to Aaron Markham and Kenneth Blackmore, relates to a sulfonated lignin-containing material and its use as an additive in drilling muds.
U.S. Pat. No. 3,634,387, to Walter Dougherty, relates to a sulfomethylated lignin-ferrochrome complex and a process for making it. A ferrochrome salt solution is used to make the lignin-containing complex. The ferrochrome salt solution is made by mixing stoichiometric amounts of a ferrous salt and a dichromate salt in order to give stability to the salt solution. A mineral acid is added to this salt solution to prevent the precipitation of hydroxides of iron or chromium upon mixing the sulfomethylated lignin solution with the salt solution.
U.S. Pat. No. 3,962,099, to Donald Whitfill, relates to a water base drilling mud composition wherein calcium ions are controlled and converted to water-insoluble plant nutrient compounds by the use of monocalcium phosphate compounds. According to this reference, at least a stoichiometric amount of a monocalcium phosphate containing compound must be added to an alkaline earth metal hydroxide.
U.S. Pat. No. 4,447,339, to William Detroit, is directed to a drilling fluid additive comprised of manganese lignosulfonates and a process for making the additive. Also described is the addition of heavy metal cations (such as iron, copper and zirconium). In one version of the process, precipitated calcium sulfate is removed from the mixture prior to complexing the heavy metal cation.
U.S. Pat. No. 4,457,853, also to William Detroit, is a continuation-in-part of U.S. Pat. No. 4,447,339, mentioned above. Boron is added to the manganese lignosulfonate to produce a manganese-boron lignosulfonate.
SUMMARY OF THE INVENTION
The present invention relates to an improved method for the making of drilling fluid additives. More particularly, the invention relates to the manufacturing of drilling fluid additives containing lignosulfonates.
It has been found that the filter plugging problem, associated with the earlier method of manufacturing chromium-free lignosulfonates, can be eliminated by carefully controlling the amounts of zirconium and/or titanium lignosulfonates which are added to the calcium lignosulfonate solution prior to filtration. It appears that highly hydrated complex metal oxides are the cause of the filter plugging problems. It also appears that adding only a stoichiometric amount reduces the amount of free titanium and/or zirconium ions that are available to form highly hydrated complex metal oxides. In particular, the amount of zirconium and/or titanium lignosulfonate should be restricted to about the stoichiometric quantity needed to react with substantially all of the calcium in the calcium lignosulfonates.
Generally, lignosulfonates, in accordance with the present invention, are prepared with a water solution of calcium lignosulfonate. A quantity of zirconium sulfate is added to the calcium lignosulfonate to form zirconium lignosulfonate and precipitate the calcium as hydrated calcium sulfate. The amount of zirconium sulfate is preferably less than the stoichiometric amount relative to the calcium and sufficient to result in not greater than about 0.5% by weight of zirconium in the final product. The remaining, unreacted calcium lignosulfonate is treated with about a stoichiometric amount of titanium sulfate to precipitate as much as possible of the remaining calcium and form titanium lignosulfonate. As discussed above, it is important that only about a stoichiometric amount of sulfate is added to react with the remaining calcium. The various components are intimately mixed to insure that the maximum amount of calcium sulfate is precipitated.
The insoluble calcium sulfate is filtered out of the mixture leaving behind primarily zirconium lignosulfonate and titanium lignosulfonate. However, it appears that a quantity of lignosulfonic acid is also present in the mixture. Therefore, a final quantity of titanium sulfate is added to the mixture so that the final product, which has been dried, preferably contains 2%-3% by weight of titanium.
A particular advantage of the present method is that the filtration of the calcium sulfate can be accomplished with greatly reduced plugging or blinding of the filter cloth. Consequently, this new method is more efficient and economical than the previous process.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred method of this invention is performed in basically three steps. First, all the chemical components are mixed in a charging tank. Second, the mixture is transferred to a rotary vacuum filter, where the hydrated calcium sulfate is removed from the mixture. Finally, the filtered mixture is pumped into a second holding tank where additional chemicals may be added to the mixture. Each of these steps is explained in detail below.
Typically, a charging tank is filled with a quantity of calcium lignosulfonate solution. The calcium lignosulfonate is typically available in a water solution containing 50%-60% by weight of calcium lignosulfonate. Next, a water solution of zirconium sulfate, typically about 18% by weight of zirconium sulfate, is added to the calcium lignosulfonate solution. The zirconium sulfate reacts with the calcium lignosulfonate to: (a) precipitate calcium sulfate; and (b) simultaneously form zirconium lignosulfonate. The amount of zirconium sulfate is substantially less than the stoichiometric amount needed to react with the calcium lignosulfonate. Preferably, the amount of zirconium sulfate should not be more than an amount sufficient to result in about 0.5% by weight of zirconium in the final product.
A stoichiometric amount of titanium sulfate is added to the mixture to substantially complete the precipitation of calcium sulfate and also form titanium lignosulfonate. The stoichiometric amount is based on the amount of sulfate required to react with substantially all of the unreacted calcium lignosulfonate. The titanium sulfate is usually dissolved in a sulfuric acid solution, typically containing about 30% by weight of titanium sulfate.
The temperature of the solution is maintained at approximately 150° F. (66° C).
In an alternative embodiment of this invention, the zirconium sulfate and titanium sulfate are added simultaneously. In another alternative embodiment, titanium sulfate is used entirely, instead of adding any zirconium sulfate. In still other embodiments, iron, aluminum and/or magnesium sulfates can be substituted for the zirconium sulfate and/or titanium sulfate.
In the preferred embodiment described earlier, hydrogen peroxide is added to the mixture in the charging tank, prior to filtration. The hydrogen peroxide oxidizes the metal lignosulfonates which have been formed. It has been found that the viscosity controlling characteristics of the additive are improved by oxidation of the metal lignosulfonates.
The hydrogen peroxide is typically available in an aqueous solution containing 50% by weight of hydrogen peroxide. The total amount of hydrogen peroxide added typically ranges from 3% to 14%, preferably 9% to 12%, by weight based on the weight of the lignin contained in the initial charge of calcium lignosulfonate. However, only a portion of the total hydrogen peroxide necessary is added to the mixture before filtration because the reaction is exothermic. This step-wise addition of hydrogen peroxide insures that the temperature of the mixture does not get substantially above 150° F. If the temperature is allowed to rise too high, flashing of the solution may occur during the following filtration step. Flashing may occur because of the lower boiling point of the solution induced by the partial vacuum caused by the filter. The remainder of the hydrogen peroxide is added after the filtration.
In each of the above embodiments, the chemical mixture is preferably transferred from the charging tank to a rotary vacuum filter of the continuous operation belt discharge type. Basically, the filter assembly is comprised of a tank with a cylinder mounted and centered inside the tank. The cylinder is hollow except for a cylindrical core which is concentric with the cylinder, and which operates as a vacuum receiver. The filter cloth typically is a 2×2 chain weave multifilament polyester dacron cloth. The filter cloth is wrapped around the cylinder and a rotating gear, located exterior of the filter tank.
The fluid is charged into the tank at least to a level which will cover the cylindrical vacuum core. The vacuum created in the cylindrical core causes the fluid to flow from the tank, through the cylinder and the filter cloth, into the cylindrical core. As the cloth is rotated around the cylinder, calcium sulfate is removed as the mixture passes through the filter cloth. The portion of the cloth which is deposited with calcium sulfate eventually emerges from the fluid at the top of the rotation of the cylinder.
The filter cloth contains both calcium sulfate and the metal lignosulfonate products. Water is sprayed on the cloth to wash the cloth of the lignosulfonate products. The remaining calcium sulfate dries as it is carried along by the cloth. When the cloth rotates around the exterior gear, the dried calcium sulfate drops off due to the angle of rotation and ridges on the gear. The filter cloth is back-washed with warm water and is ready to remove more calcium sulfate.
The filtered mixture is transferred into a holding tank. Additional chemicals are added which further modify the lignosulfonates. A second amount of titanium sulfate is normally added to the filtered mixture. It has been found that the best viscosity control characteristics are obtained when the final product contains 2%-3% by weight of titanium. It is believed that the additional titanium lignosulfonate reacts with lignosulfonic acid contained in the filtrate. The remainder of the hydrogen peroxide is also added to the mixture to complete the oxidation of the metal lignosulfonates.
Although the preferred embodiments of this invention have been described hereinabove in some detail, it should be appreciated that these embodiments are capable of variation and modification. The description of this invention is not intended to be limiting, but is merely illustrative of the preferred embodiments.
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An improved process for making drilling fluid additives. The drilling fluid additives generally comprise titanium and/or zirconium lignosulfonates. The improved process of this invention can be performed without any delays caused by plugging during filtration. Filtration plugging problems are eliminated by adding only stoichiometric amounts of zirconium and/or titanium lignosulfonate to the lignosulfonate mixture prior to filtration.
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BACKGROUND OF THE INVENTION
This invention relates to a method of chlorinating the side chains of aromatic and heterocyclic ethers. In particular, it relates to performing such chlorinations in aliphatic fluorinated solvents.
Until recently, aryl ethers were chlorinated in carbon tetrachloride. However, carbon tetrachloride is now considered to be environmentally deleterious and its use as a solvent for this type of reaction is no longer permitted. Thus, a search has been conducted by the chemical industry to find other acceptable solvents for this reaction. For example, U.S. Pat. Nos. 5,440,051 and 5,484,932 disclose performing these chlorination reactions in certain aromatic solvents. The substrate--the compound to be chlorinated--is dissolved in the aromatic solvent for the chlorination reaction. After the chlorination is complete, the product, which is also soluble in the solvent, is separated from the solvent by distillation.
SUMMARY OF THE INVENTION
We have discovered that side chains on aromatic and heterocyclic ethers can be chlorinated in aliphatic fluorinated solvents. We have further discovered that these solvents offer a number of advantages over aromatic solvents, such as those described in the prior art. For example, for many substrates and fluorinated solvents, the product is insoluble in the solvent so that two phases form--a product phase and a solvent phase. Thus, the product is easily separated from the solvent and distillation to separate the product from the solvent is eliminated. Because two phases are formed, the solvent can be easily recycled and reused and the process can be run continuously. Many of the fluorinated solvents of this invention are unreactive, non-toxic, environmentally acceptable, and non-flammable.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Substrate
The process of this invention can be applied to chlorinate a methyl or ethyl hydrogen on a side chain of a aromatic or heterocyclic ether (α-chlorination). In particular, the substrate has the formula ROR', where R is methyl or ethyl, R' is a group containing an aromatic ring or a heterocyclic ring, and the RO group is bonded directly to that aromatic or heterocyclic ring. The R' group preferably contains an aromatic ring as those substrates are commercially more important. Examples of aromatic rings include benzene, naphthalene, and anthracene. A single benzene ring is preferred, and the most preferred substrates are methoxybenzenes, such as anisole or a substituted anisole, which have the formula: ##STR1## where each R 1 is independently selected from NO 2 , X, CX 3 , or OCX 3 , where each X is independently selected from halogen and n is an integer from 0 to 3. If n is 1, R is preferably chlorine and is preferably in the para position as those substrates are more important commercially than other substituted methoxybenzenes. Examples of substituted methoxybenzenes include 4-chloroanisole (4-chloromethoxybenzene), 2-, 3-, or 4-fluoroanisole, 3-(trifluoromethyl) anisole, and 3-methoxy-5-(trifluoromethyl) aniline. However, the preferred substrate is anisole (n=0) because the chlorination product, α,α,α-trichloromethoxybenzene (TCMB), is a commercially important product.
Heterocyclic rings can have 5 or 6 atoms in the ring and the hetero atom (or atoms) can be nitrogen, sulfur, or oxygen. Examples of substrates containing a heterocyclic ring include 2-methoxypyridine, 4-methoxypyridine, 2-methoxypyrazine, 4-methoxypyrazine, 2-methoxythiophene, and 4-methoxythiophene.
Fluorinated Solvent
The fluorine-containing solvents useful in this invention are aliphatic compounds (i.e., they do not contain an aromatic ring) that boil between 50° and 110° C. The solvents are either liquid at room temperature or are liquid at the reaction temperature; preferably, they are liquid at room temperature as those solvents are easier to use. Preferably, the product of the reaction is immiscible with or insoluble in the solvent, so that the product can be easily separated from the solvent without using distillation. The solvent must be unreactive with the substrate and with the chlorine radical. Examples of suitable solvents include fluorocarbons (i.e., perfluorocarbons and hydrofluorocarbons), perfluorocycloalkanes, perfluorinated nitrogen-containing ring compounds, and fluoroethers.
Examples of fluorocarbons include compounds having the general formula C m H n F 2m+2-n , where m is 6 to 10, and n is 0 to m/2 if m is even and 0 to (m+1)/2 if m is odd. Perfluorocarbons (i.e., n=0) are preferred over hydrofluorocarbons (i.e., n≧1) because they are immiscible with product, which facilitates separation after chlorination. Examples of suitable perfluorocarbons include perfluorohexanes, and perfluoroheptanes. The preferred perfluorocarbon is perfluorohexane because its boiling point is low and ring chlorination is minimized when the reaction is performed at reflux and the reflux temperature is low (i.e., below 60° C.). Examples of suitable hydrofluorocarbons include 2,3-dihydrodecafluoropentane (DHDFP), 1-hydrotridecafluorohexane, and nonafluoro-hex-1-ene. The preferred hydrofluorocarbon is DHDFP because it is commercially available.
Perfluorocycloalkanes are ring compounds containing only carbon and fluorine. Examples include perfluorocyclohexane, perfluoromethylcyclohexane, perfluoro-1,2-dimethylcyclohexane, perfluoro-1,3-dimethylcyclohexane, perfluorocycloheptane, and perfluorocyclooctane. The preferred perfluorocycloalkane is perfluorocyclooctane because its boiling point allows operation at reflux with minimum loss through the condenser.
Perfluorinated nitrogen-containing ring compounds are ring compounds having a nitrogen in the ring, where all the single bonds are to fluorine. Examples of perfluorinated nitrogen-containing ring compounds include perfluoro(4-methyl morpholine), C 5 F 11 NO, which has the structure: ##STR2## and perfluoro(N-methyl piperidine), C 6 F 13 N, which has the structure: ##STR3## Both compounds are commercially available.
Linear fluoroethers include compounds having the general formula F 2p+1-q H q C p --O--C r H s F 2r+1-s , where p and r are each independently selected from integers from 3 to 6, q is an integer from 0 to 2p, and s is an integer from 0 to 2r+1. Examples of suitable linear perfluorethers (i.e., q=0 and s=0) include bis(perfluoropropyl)ether, bis(perfluorobutyl)ether, and bis(perfluoropentyl)ether. The preferred perfluoroether is bis(perfluorobutyl)ether because its boiling point allows operation at reflux with minimum loss through the condenser. Examples of alkyl perfluoroethers (i.e., q=0 and s=2r+1) include (perfluoroisopropyl)ethyl ether, (perfluoroisopropyl)methyl ether, (perfluorobutyl)methyl ether, and (perfluorobutyl)ethyl ether. (Perfluoro)isopropylethyl ether is preferred because its vapor pressure is close to the vapor pressure of BTF. Cyclic perfluoroethers, such as ##STR4## sold by ACROS as "FC-75" solvent and perfluoropolyethers, such as ##STR5## where t is between 1 and 8 and u is between 1 and 20 (sold as "Fomblin" solvent by Ausimont), can also be used.
The preferred fluorinated solvent is perfluorohexane because perfluorohexane contains few other isomers and therefore isomer peaks do not show when the reaction is followed by gas chromatography (GC). The amount of fluorinated solvent should be about 10 to about 90 wt %, based on the weight of the composition. If less fluorinated solvent is used, ring chlorination may increase and more solvent is unnecessary and is a waste of reactor volume. Preferably, about 40 to about 70 wt % fluorinated solvent is used.
Chlorine Radical
The substrate is chlorinated with gaseous chlorine that has been split into the chlorine radical Cl·. Any source of chlorine radicals can be used in this reaction. While UV light is preferred for generating chlorine radicals, a free-radical initiator can be used instead. Examples of suitable free-radical initiators include azo compounds such as 1,1'-azobis(isobutyronitrile) (AIBN) and 1,1'-azobis(cyclohexane carbonitrile), NCC 6 H 10 N═NC 6 H 10 CN, sold by Dupont as "VAZO," and peroxides such as benzoyl peroxide, diacetyl peroxide, and succinyl peroxide. The preferred free-radical initiator is VAZO because of its long half life at 88° C. (10 hours). If a free-radical initiator is used, the amount should be about 0.01 to about 10 wt %, based on the weight of substrate. If less free-radical initiator is used, the reaction is too slow and more initiator is unnecessary. Preferably, the amount of free-radical initiator is about 0.1 to about 1.0 wt %.
Chlorination Reaction
The chlorination reaction is performed by heating the mixture of the reactants until the product forms. The reaction temperature will depend upon the particular substrate used. For example, anisole is preferably heated at a temperature of about 60° to about 120° C. We have discovered that it is preferable to keep the reaction temperature at reflux as that seems to result in the production of less chloro-phenol by-products. We have also found that it is preferable to meter into the solvent stoichiometric quantities of the substrate and the chlorine as this seems to result in less ring chlorination. Also, it is preferable to perform the reaction continuously as this is more efficient and less costly. The end of the reaction can be determined by gas chromatography (GC).
The chlorinated product is generally a liquid which, if a preferred solvent is used, will be insoluble in the solvent, resulting in the formation of two phases, a product phase and a solvent phase. The two phases can be easily separated by, for example, decantation, thereby eliminating a distillation step. The solvent can be recycled as the product is removed.
The following examples further illustrates this invention.
EXAMPLE 1
Into a 250 mL photochlorination apparatus equipped with a 100 W medium pressure Hanovia UV light (air cooled), a reflux condenser, an inlet for the addition of anisole, a thermocouple, and an inlet for chlorine was placed 500 g of "FC-75" solvent. The reactor was heated to reflux (102° C.), by means of a thermal tape around the apparatus and a light. Both chlorine and anisole were metered into the reactor at the same time. The chlorine was added at a rate of 243 mL/min for half an hour, and then at 164 mL/min for the remainder of the reaction. The anisole (35 g, 7 wt %, based on the weight of the solvent) was added at a rate of 30 g/hr using an FMI pump. Both anisole and the product of the reaction were immiscible with the solvent. The product was the top layer of the two layers in the reactor. An assay of the top layer by GC showed a 92.3% yield of the desired TCMB.
EXAMPLE 2
Example 1 was repeated with similar results using 392 g of perfluorohexane, C 6 F 14 , sold by ACROS as "FC-72" solvent. The reactor was heated to reflux (55° C.). The chlorine was added at a rate of 200 mL/min for an hour, and then at 100 mL/min for the remainder of the reaction. The anisole (69.2 g, 17.65 wt %, based on the weight of the solvent) was added at a rate of 30 g/hr. The yield of TCMB was 93.5%.
EXAMPLE 3
Example 1 was repeated with similar results using 496.6 g of "Fomblin" solvent. The reactor was heated to reflux (109° C.). The chlorine was added at a rate of 200 mL/min for three hours, and then at 100 mL/min for the remainder of the reaction. The anisole (88.4 g, 17.8 wt %, based on the weight of the solvent) was added at a rate of 30 g/hr. The yield of TCMB was 89.8%.
EXAMPLE 4
Example 1 was repeated with similar results using 377 g of hydrofluoroether, C 5 H 3 F 9 O, sold by 3M as "HFC-7100" solvent. The reactor was heated to reflux (60° C.). The chlorine was added at a rate of 243 mL/min for four hours. The anisole (55 g, 14.6% by weight of the solvent) was added at a rate of 30 g/hr. The yield of TCMB was 93.9%.
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Disclosed is a method of chlorinating a side chain of a aromatic or heterocyclic ether. The aromatic or heterocyclic ether is mixed with a fluorine-containing aliphatic solvent. The aromatic or heterocyclic ether is contacted with chlorine radical at an elevated temperature which results in its chlorination. The chlorinated product is preferably insoluble in the solvent and separates, forming two phases. The solvent phase can be recycled and reused.
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