description
stringlengths 2.98k
3.35M
| abstract
stringlengths 94
10.6k
| cpc
int64 0
8
|
|---|---|---|
BRIEF SUMMARY OF THE INVENTION
This invention relates generally to the removal of polymers from various reuseable objects, for example molded inserts and polymer processing equipment such as spin packs, filters, melt pumps, and the like. More particularly, the invention relates to a technique for the removal of condensation polymers by hydrolysis. In general, it is desirable that such technique be economical, safe, environmentally acceptable and not damaging to the structural or metallurgical properties of the hardware being cleaned.
None of the techniques in common use meet all of the above goals. The deficiencies in each depend on the type of polymer and the particular technique used. Two of the techniques in common use by the polymer processing industries for removing polymers from process hardware are (1) the use of solvents such as glycols, methylene chloride or other common solvent reagents, and (2) thermal techniques such as the use of a fluidized, heated granular bed, a molten salt bath or a vacuum or inert atmosphere furnace.
Solvent techniques are generally employed at temperatures low enough to avoid any disturbance of the metallurgical properties of the hardware. However, the most efficient cleaning action occurs at temperatures greater than the normal boiling points of the solvents, thus necessitating the use of pressure vessels. The use of such vessels is undesirable because of the inherent cost involved and the requirement for seals and safety locks. Non-pressurized solvent cleaning systems typically evolve fumes and may require extended cleaning cycles. The cost of chemicals may be prohibitively high. Further, the problem of disposing of, treating or reclaiming the by-products from the solvent vessel in a cost effective and environmentally safe manner may present a considerable difficulty. In some cases, the use of solvents may give rise to a possibility of explosion.
In thermal techniques the cleaning is accomplished by heating to a temperature sufficient to cause degradation of the polymer. The part to be cleaned is usually heated to about 400° to 510° C. These techniques usually include the limited introduction of air to complete the degradation. The introduction of air is limited by immersing the part in a partial vacuum or partial inert atmosphere such as steam or inert gases. At the temperatures used, the degradation of the polymer is accompanied by the evolution of certain volatile components in the compound. Any emissions resulting from such cleaning must usually be treated to reduce particulates and potentially toxic volatile hydrocarbons. Also, there is a possibility of thermally damaging the part to be cleaned.
The prior art further includes in situ methods for removing condensation polymers including their degradation by hydrolysis, as described for example in U.S. Pat. No. 3,510,350 to Priebe. This patent describes a technique for cleaning nylon transfer systems by subjecting pipelines heated by external sources to saturated steam. This technique requires the use of elevated pressures, for example 17.58 Kg. per cm 2 (250 psi), with the attendant problems previously mentioned.
With a view to overcoming the several objectionable features of the techniques described above, the present invention is characterized by its use of hydrolysis reactions to remove from objects coatings of condensation polymers of those types that are decomposable by hydrolysis. The reactions are characterized in a physical aspect by a reduction in the melt viscosity of the polymer, allowing a portion to drip from the object, and in a chemical aspect by the water vapor entering into a reversal of the polymerization reaction, with monomers and other species being evolved and entrained in the moving stream of the vapor.
To this end, the invention employs an enclosed vessel through which superheated water vapor is circulated, the vapor serving to heat the objects and being maintained at a temperature above the melting point of the polymer but below that which causes damage to the objects being cleaned. The pressure within the vessel is sufficient to exclude ambient air from contact with the objects to be cleaned, and in many applications it is only slightly above atmospheric.
BRIEF DESCRIPTION OF THE DRAWING
The drawing is a partly schematic illustration of the presently preferred embodiment of a system performing the process of this invention.
DETAILED DESCRIPTION
Referring to the drawing, equipment for carrying out the process according to this invention, designated generally at 12, includes a process chamber 14, a steam boiler 16, a superheater 18, a circulation blower 20 and a holding tank 22. The arrows indicate the directions of flow of steam and superheated water vapor within the system as described below.
The process chamber is preferably an insulated horizontal cylindrical steel vessel having a closed end and an access door 24. A suitable carriage mechanism (not shown) is mounted externally and in front of the door in position for fixturing and loading onto a suitable support 26 the objects or parts to be cleaned of polymer. These parts are represented for purposes of illustration by a part 30, and are preferably situated in a position that will facilitate the flow of steam and water vapor around and in contact with the surfaces coated with polymer.
The steam boiler 16 is of conventional construction and is adapted to deliver steam at a selected weight rate per unit of time through a pipe 32 into an elongate superheating chamber 34. A pipe 36 is located so that steam from the boiler 16 passes over the superheater 18 and through the pipe 36 into the confined space 28. A pipe 38 is located at the end of the space 28 in position to deliver steam and water vapor back to the blower 20.
A vent line pipe 40 is let into the pipe 38 and has an open end 42 within the holding tank 22. The end 42 is immersed to a height "h" in a body of water 44, the value of "h" being preferably of the order of 30 cm.
A primary trap 46 is located below the process chamber or vessel 14 and connected thereto by a pipe 48. The trap is a metal enclosure with an access door 50, and is located so that molten polymer dripping from the part 30 will fall and flow by gravity through the support 26, which is preferably an open mesh wire screen or the like, onto a drip pan 51 with sloping sides, and thence through the pipe 48 into a body 52 where it is congealed for ready removal.
The presently preferred process using the apparatus of the drawing is initiated upon the placing of the part or parts 30 to be cleaned into the space 28, with the access door 24 being then sealed. The steam boiler 16 is then fired and the blower 20 is started. When steam begins to be generated, it passes through the pipe 32, enters the chamber 34 and then follows a recirculation path from the chamber 34 to the pipe 36, through the space 28, the pipe 38 and the blower 20, back to the chamber 34. At the same time, a fraction of the steam passing through the pipe 38 enters the vent line 40 and passes out of the end 42 into the body of water 44. The fraction of the steam passing through the pipe 38 that enters the vent line 40 is a function of the steam flow rate generated by the boiler 16.
Following the initial start-up of the blower 20, air within the system including the space 28 is entrained in the circulating steam including the steam which passes out through the vent line 40. In this manner, the steam progressively displaces the air from the space 28.
The superheater 18 is fired when the steam entering the system has caused the pressure to rise to a predetermined level, thereby causing the progressive elevation of the temperature of the circulating steam, and the steam ultimately passes from the saturated state to the superheated state. Since the system is at nearly atmospheric pressure, this occurs at a temperature of approximately 100° C. Thereafter, superheated water vapor continues to flow in a stream through the space 28 around and over the part 30. The temperature of the water vapor continues to rise and ultimately reaches a predetermined value in the range between 270° and 400° C. For typical condensation polymers, the melting temperature is reached at approximately the lower end of this range, and within this range hydrolysis action takes place at a rapid rate.
As the polymer reaches the melting temperature, it flows from the part 30, falling under the force of gravity to the drip pan 51 and thence through the pipe 48 to the trap 46. Since the trap 46 is relatively isolated from the space 28 and not in direct contact with the moving stream of superheated water vapor, it is at a lower temperature than the space 28, typically low enough to allow the polymer to solidify at 52, thereby being removed from the cleaning process.
Since the source of heat for the part 30 in this process comprises only the moving stream of superheated water vapor, the surfaces of the polymer coating the part are at the highest temperatures in the part 30, and are rapidly hydrolyzed by reaction with the moving stream of vapor. The relative motion between the vapor stream and the surfaces of the polymer coating assures a constantly replenished supply of water vapor for supporting the hydrolysis reaction with those surfaces. Moreover, as molten polymer flows and drips from the surfaces, the surfaces themselves are constantly renewed and replaced by fresh surfaces of unreacted polymer for exposure to the moving vapor.
Products of hydrolysis are entrained in the moving stream of vapor which then enters the pipe 38. One portion of this stream is recirculated through the blower 20, the chamber 34 and the pipe 36 back through the space 28 and another fraction is drawn off through the vent line 40. Vapor with entrained products passes through the opening 42 into the water 44 which traps many of the products.
After the process has continued for a sufficient length of time, the superheater 18 is shut off and a cooldown cycle begins. Preferably, during this cycle the boiler 16 and blower 20 continue to operate until the superheated water vapor has been reduced in temperature to a value below the melting point of the polymer at which the part 30 may be safely removed. Finally, the boiler and blower are shut down and the door 24 may be opened to retrieve the cleaned part 30.
In the above-described process the superheated water vapor performs three distinct functions. First, it is a heat transfer medium by means of which heat is applied to the part 30 to elevate the polymer coating thereon to the desired temperature, there being a continuous relative motion between the moving stream and the surfaces of the part 30. Second, the superheated water vapor acts as a purge and blanket medium, shielding the part 30 with its heated coating from contact with air and minimizing oxidation. Third, the water vapor comprises the hydrolysis process reagent as above described.
Certain variations in the above-described process may be carried out, as described above and as will be further evident to one skilled in the art. For example, thermostatic sensors can be installed to monitor temperatures at various points in the system. Timers may also be employed for starting and stopping the operation, of the boiler 16, the superheater 18 and the blower 20 as functions not only of time but also of the temperature within the space 28. The height "h" of the head of water may be varied, but in any event is not sufficient to elevate the pressure within the system substantially above atmospheric. The pressure is typically less than 15 psig. Also, alternate means may be employed to restrict the outlet flow in order to maintain the desired pressure in the system. In the above-described illustration the value of "h" is approximately 30 cm, elevating the pressure within the space 28 to only about 30 gm. per cm. 2 (0.43 psi.) above atmospheric. Also, variations in temperatures of processing can be employed to accommodate the particular types of condensation polymers to be removed.
|
Condensation polymer coatings are removed from various objects to permit their reuse. Superheated water vapor flows in contact with the coating surfaces, excluding air therefrom while heating them to temperatures above the melting point of the polymer. The water vapor further enters into an hydrolysis reaction with the polymer to decompose it.
| 2
|
FIELD OF THE INVENTION
[0001] The invention relates to methods for attaching ink jet filters to an ink cartridge for an ink jet printer, and in particular to apparatus for reliable filter attachment to the cartridge.
BACKGROUND
[0002] Ink jet printers have achieved wide acceptance in the field of printing and continue to make great strides towards high speed, high quality printing. In order to improve the quality and speed of printing, nozzle plates having a larger number of smaller orifices are provided. As the size of the orifices continue to decrease, components of the ink cartridge assembly become increasingly more important. A component of the ink cartridge that is particularly important for proper operation of an ink jet printhead attached to the cartridge is a filter disposed between an ink reservoir and a flow path for ink to the printhead. The filter is the first and most important line of protection for large or foreign particles entering ink flow features of the printheads. Particles larger than the flow features of the printhead can adversely affect the operation of the printhead thus dramatically decreasing the quality and operation of the printhead.
[0003] The most widely used filter material for application in an ink cartridge is a Dutch weave stainless steel material. Metal filters are typically attached to a filter assembly in the ink cartridge by hot stamping the metal filter onto a plastic frame using a hot block or hot die. Melted plastic from the frame is squeezed into the filter mesh to create a mechanical interlock between the frame and the filter. However, the cost of such stainless steel material is relatively high.
[0004] In order to reduce the cost of the filter and to provide better wetting of the filter during the melting process, synthetic fiber filter materials have been selected for providing filters. Such synthetic fiber materials include acrylics, nylon, polyester, polyethylene, polypropylene, and polyvinylehloride. However, the replacement of metal filter material with synthetic filter materials, makes attachment of the filter to the frame much more difficult. In a hot stamping process, heat must be transferred from the hot block to the filter material and then to the filter frame. If the melting temperature of the frame is lower than that of the filter material, the frame material will be squeezed into the pores of the filter and create a mechanical lock as before. On the other hand, if the melting temperature of the frame is higher than that of the filter material, the filter will be melted and thinned under pressure, and in some cases the stitches around the perimeter of the filter may be damaged thereby weakening the filter.
[0005] Ultrasonics may also be used to attach plastic materials to one another. However, when ultrasonics are applied to synthetic filter materials, the high frequency mechanical vibration may cause loose stitches, broken stitches, and particle generation. Loose stitches and broken stitches may cause the filter to fail prematurely. Particle generation may inhibit the flow of ink to and in the ink jet printheads thereby reducing print quality. Another disadvantage of plastic filter materials is that these materials are generally less stiff than metal filter materials and are thus prone to bending, stretching, and wrinkling during the attachment process.
[0006] Thus, there continues to be a need for improved low cost filter materials and improved methods for attaching the filter materials to a frame in an ink cartridge for an ink jet printhead.
SUMMARY OF THE INVENTION
[0007] With regard to the foregoing and other objects and advantages, the invention provides an apparatus for a laser transmission welding process for attaching a synthetic filter material to a filter tower frame in an ink jet printer cartridge. The apparatus includes a filter clamping fixture having a base, slide rods attached on first ends thereof to the base, an optics support plate attached to second ends of the slide rods, a movable platform for holding an ink cartridge slidably disposed on the slide rods between the base and the optics support plate, a platform moving device for translating the platform to and from a laser welding position, a laser beam transparent plate suspended by support legs from the optics support plate to a position between the movable platform and the optics support plate, and a laser beam source for heating an interface between the synthetic filter material and the filter tower frame to weld the filter material to the frame.
[0008] In another embodiment, the invention provides a method for attaching a synthetic filter material to a filter tower frame in an ink jet printer cartridge. The method includes providing a laser beam source and a filter clamping fixture for laser beam transmission welding of the filter material to the filter tower frame. The clamping fixture includes a base, slide rods attached on first ends thereof to the base, an optics support plate attached to second ends of the slide rods, a movable platform for holding an ink cartridge slidably disposed on the slide rods between the base and the optics support plate, a platform moving device for translating the platform to and from a laser welding position, and a laser beam transparent plate suspended by support legs from the optics support plate to a position between the movable platform and the optics support plate. The ink cartridge having a filter tower frame therein is placed onto the movable platform. The synthetic filter material is positioned onto the filter tower frame in the ink cartridge. The movable platform is moved toward the laser beam transparent plate so that the synthetic filter material is disposed between the transparent plate and the filter tower frame and is in intimate contact with a perimeter of the filter tower frame. The synthetic filter material is then laser welded to the filter tower frame by heating the perimeter of the filter tower frame with a laser beam from the laser beam source having sufficient power to melt a portion of the filter tower frame for melt flow of the portion of the frame through pores in the synthetic filter material.
[0009] In yet another embodiment, the invention provides an ink cartridge for an ink jet printer, the cartridge containing a filter tower frame and a polyester filter material attached to perimeter of the filter tower frame using a laser beam transmission welding process. The polyester filter material attached to the frame has a laser beam transmission rate of at least 50% or more for laser beam wavelengths ranging from about 750 to about 1200 nanometers. The filter tower frame has a laser beam absorption rate of greater than about 50% for laser beam wavelengths ranging from about 750 to about 1200 nanometers. At least a portion of the perimeter of the filter tower frame is melt-flowed into pores of the filter material by the laser welding process.
[0010] The invention provides a number of advantages over conventional apparatus and methods for attaching filter materials in ink jet cartridges. In particular, the process and apparatus enables use of a synthetic filter material which is less costly than a metal filter material. The apparatus also enables welding of synthetic filter materials to a filter tower structure while maintaining the filter material in a desired shape. For example, contoured or tented filters may be attached to filter towers using the apparatus according to the invention. Another advantage of the invention is that the process of laser welding is substantially a non-contact process thereby avoiding abrasion of the filter material. As compared to ultrasonic welding, the laser welding process according to the invention does not cause vibrations during the welding process which can generate particles or otherwise damage the filter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The above and other aspects and advantages of the invention will become further apparent by reference to the following detailed description of preferred embodiments when considered in conjunction with the accompanying drawings in which:
[0012] FIG. 1 is schematic representation of a laser transmission welding process according to the invention;
[0013] FIG. 2 is side elevational view, not to scale, of an ink cartridge containing a filter welded to a filter tower according to the process of the invention;
[0014] FIG. 3 is a side elevational view, not to scale, of a laser transmission welding fixture for use in the process of laser transmission welding according to the invention;
[0015] FIG. 4 is a partial perspective view, not to scale, of an upper portion of a laser transmission welding fixture according to the invention;
[0016] FIG. 5 is a detailed view, not to scale, of a transparent plate and support legs for a laser transmission welding fixture according to the invention;
[0017] FIGS. 6A and 6B are side elevational view of a fixture according to the invention during a laser transmission welding process;
[0018] FIG. 7 is a detailed side view of an alternate filter shape and an alternate transparent plate for use with a laser transmission welding fixture according to the invention;
[0019] FIG. 8 is a detailed side view of another alternate filter shape and another alternate transparent plate for use with a laser transmission welding fixture according to the invention;
[0020] FIG. 9 is a detailed side view, not to scale, of a transparent plate for use in welding a filter to a filter tower frame according to another embodiment of the invention;
[0021] FIG. 10 is a plan view, not to scale, of the transparent plate of FIG. 9 ; and
[0022] FIGS. 11 and 12 are plan views, not to scale, of transparent plates and support legs for laser welding a filter to an angled filter tower frame according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] With reference to FIG. 1 , a schematic representation of a laser transmission welding process 10 for attaching a synthetic filter to a filter tower structure is shown. According to the process, a laser beam 12 is focused through a lens 14 onto an interface 16 between a first material 18 to be welded to a second material 20 . For this process, it is important that at least one of the two materials being joined together be substantially transparent to the laser beam 12 .
[0024] The material facing the laser source, the first material, may preferably be clear or colored provided the coloring material or pigment does not significantly affect the transmission of the laser beam through the material. The second material is placed on a side of the first material opposite the laser beam side of the first material. The second material must be able to absorb the laser beam 12 so that it heats up and melts during the welding process.
[0025] It is also important that the two materials be in intimate contact with each other during the welding process. As the second material absorbs the laser energy and heats up it also heats up the first material in contact with it thereby also melting a portion of the first material in contact with the second material. Hence, the laser beam transmission rate of the first material is an important factor in use of the laser transmission welding process. If the transmission rate is too low, the energy absorbed by the material facing the laser beam 12 may overheat and degrade before the laser energy is transmitted to the second material.
[0026] In this case, the first material 18 is preferably a synthetic filter material having a laser beam transmission rate of greater than about 50% at laser beam wavelengths in the near infrared (NIR) spectrum. The second material 20 preferably has a laser beam absorption rate of greater than about 50% at laser beam wavelengths in the NIR spectrum. Particularly preferred wavelengths range from about 750 to about 1200 nanometers. It is also preferred that the melting point of the first material 18 be higher than the melting point of the second material and that the melting point of the first and second materials be no more than 30° C. apart. It is also preferred that the first and second materials 18 and 20 be compatible with each other so that there is intimate mixing of the first and second materials at the interface 16 thereof.
[0027] With reference to FIG. 2 , a simplified drawing of an ink cartridge 22 for an ink jet printer is illustrated. The ink cartridge 22 includes a cartridge body 24 for providing an ink reservoir 26 therein. Disposed in the ink reservoir is an ink filter 28 attached to a filter tower frame 30 . A particularly preferred ink cartridge 22 includes a body 24 molded from a material selected from the group consisting of thermoplastic materials including but not limited to polyphenylene oxide/polystyrene alloys, polypropylene, acrylonitrile/buta-diene/styrene terpolymers, polystyrene/butadiene alloys or copolymers, polyetherimide, polysulfone, polyesters and the like, having a melting point or softening point above about 120° C. A particularly preferred material for the ink cartridge body is a polyphenylene ether/polystyrene resin from GE Plastics of Pittsfield, Mass. under the trade name NORYL SE1701.
[0028] The filter tower frame 30 is preferably made of a material that is chemically compatible with the synthetic filter material and is able to absorb a substantial amount of radiation from a laser source. Particularly preferred materials for providing the filter tower frame 30 include thermoplastic polyester materials such as a glass reinforced polyethylene terephthalate material available E. I. DuPont Company of Wilmington, Del. under the trade name RYNITE FR515. Other preferred materials that may be used for providing the filter tower frame 30 include, but are not limited to, polybutylene terephthalate materials available from GE Plastics of Pittsfield, Mass. under the trade names VALOX 357 and VALOX 855. A laser absorption dye or a pigment such as carbon black is preferably included in the resin for making the filter tower frame 30 in order to increase the absorption of the laser beam radiation so as to melt a portion of the filter tower frame 30 around a perimeter thereof during the welding process. The percentage of pigment dispersed in the material for the filter tower frame 30 may range from about 0.2% to about 2% by weight.
[0029] In order to effectively weld the filter 28 to the filter tower frame 30 , the filter 28 is preferably made of a woven synthetic thermoplastic material having a substantial laser beam radiation transmission rate at the near infrared spectrum (NIR). Accordingly, it is preferred that the filter material be selected from a polyester material such as a woven polyester available from Saati SpA Corporation of Milano, Italy under the trade name SAATIFIL. It is particularly preferred that the filter material be chemically compatible with the filter tower frame material so that upon melting of a portion of the filter tower frame material, the molten filter tower frame material will wet and the filter material and form a bond with the filter material fibers. The laser beam transmission rate of the filter material is preferably greater than about 50% in at near the NIR spectrum.
[0030] Another important aspect of the invention is that there is preferably intimate contact between the filter 28 and the filter tower frame 30 during the laser welding process. Intimate contact between the filter 28 and frame 30 insures that there a solid perimeter around the filter is provided so that ink in the ink reservoir 26 cannot bypass the filter and get into minute flow features in a printhead attached to the ink cartridge 22 . Intimate contact is preferably obtained by use of a laser transmission welding fixture 32 generally as shown in FIG. 3 .
[0031] With reference to FIG. 3 , the laser transmission welding fixture 32 includes a base plate 34 , a moving plate 36 , and a top plate 38 . The top plate 36 and base plate 32 are connected to one another by slide rods 40 so that the base plate 32 is attached on a first end 42 of the slide rods 40 and the top plate 36 is attached on a second end 44 of the slide rods 40 . The movable plate 36 is movably positionable between the top plate 38 and the base plate 34 by, for example, an electric or hydraulic cylinder 48 and push rod 50 . Accordingly, the movable plate 36 is freely slidable in the direction of arrow 46 along a portion of the length of the slide rods 40 .
[0032] The upper plate 38 includes an opening 52 therein ( FIG. 4 ) for transmission of a laser beam 54 from a laser source 56 to a workpiece placed on movable plate 36 . A preferred laser beam source 56 is a diode laser having a wavelength ranging from about 750 to about 1200 nanometers. An Nd:YAG laser may also be used to provide the laser beam source 56 . A laser beam transparent plate 60 is attached to support legs 62 which are attached to the top plate 38 so that the transparent plate 60 is fixedly suspended between the top plate 38 and the movable plate 36 . The support legs 62 enable the transparent plate 60 to resiliently contact a surface of the workpiece as described in more detail below.
[0033] A more detailed view of the transparent plate 60 and support legs 62 is shown in FIG. 5 . The transparent plate 60 may be provided by glass, clear polycarbonate, clear polymethyl methylacrylate, cyclic olefin polymer, or quartz. A particularly preferred material for the transparent plate is glass. The transparent plate 60 preferably has a thickness ranging from about 8 to about 12 millimeters for glass and from about 18 to about 25 millimeters for polymeric or plastic materials.
[0034] The transparent plate 60 is attached to the support legs 62 with a resilient pad 64 interposed between an end 66 of legs 62 and the transparent plate 60 . The resilient pad 64 may be made of natural or synthetic rubbers such as neoprene rubber or a thermoplastic elastomer available from Advanced Elastomer Systems of Akron, Ohio under the trade name SANTOPRENE.
[0035] Use of a resilient pad 64 between the legs 62 and transparent plate 60 is important to maintain the plate 60 in intimate contact with the workpiece such as filter 28 on filter tower frame 30 as pressure is applied to the filter 28 and filter tower frame 30 during the welding process. As with all molded plastic parts, there is some variation in the height or planarity of the perimeter of the filter tower frame 30 . The resilient pad 64 enables full surface contact between the filter 28 and the transparent plate 60 regardless of variations in the height or planarity of the filter tower frame 30 . During the welding process, the transparent plate 60 is pressed against the filter 28 and filter tower frame 30 with a pressure ranging from about 1500 to about 3000 mm Hg.
[0036] An opposite surface 68 of the transparent plate 60 is preferably coated with a release coating material 70 such as silicone, siloxane, parylene, or fluoropolymer coating materials. A particularly preferred coating material is a fluoropolymer coating material available from the E. I. DuPont Company under the trade name TEFLON. The release coating material 70 is preferably substantially transparent to laser beam radiation in the near infrared spectrum, most preferably having a laser beam transmission rate of at least about 80% at wavelengths ranging from about 750 to about 1200 nanometers.
[0037] During the laser transmission welding process, the perimeter 72 of the filter tower frame 30 is heated to the melting point of the frame material. As a portion of the frame 30 melts, it flows through pores in the filter 28 and adheres to the coating material 70 on the transparent plate 60 . If the filter tower material is not removed from the transparent plate 60 , it will absorb laser energy from the laser beam 54 and may burn or crack the transparent plate 60 . Filter tower material stuck to the transparent plate 60 may also stick to and cause separation between a filter 28 and filter tower 30 on the next welding cycle. Accordingly, the coating material 70 serves to protect the integrity of the welded structures and to prevent damage to the welding fixture 32 .
[0038] The entire fixture 32 is preferably positioned atop an XY translation table 74 for moving the fixture 32 under the laser beam 54 during the welding process. By moving the fixture 32 and workpiece on the fixture 32 , a stationary laser beam source 56 may be used to perform the welding operation.
[0039] A process for laser transmission welding of the filter 28 to the filter tower frame 30 is illustrated schematically in FIGS. 6A and 6B . After completion of a welding procedure, the movable plate 36 is lowered by cylinder 48 and piston 50 to a first position indicated by arrow 76 . An ink cartridge 22 is placed in the welding position on movable plate 36 so that the filter tower 30 and filter 28 align generally with the position of the transparent plate 60 . During this step, the laser beam from the laser source 56 is not turned on.
[0040] Next, cylinder 48 is activated to extend piston 50 therefrom and move movable plate 36 to a second position indicated by arrow 78 wherein the transparent plate 60 is in intimate contact with the filter 28 inside the ink cartridge 22 . The laser source 56 is activated to provide laser beam 54 for welding the filter 28 to the filter tower frame 30 while the XY table moves the entire fixture 32 in the X and Y directions so that a weld can be provided around the perimeter of the filter tower frame 30 . Upon completion of the welding process, the movable plate 36 is again lowered to the first position indicated by arrow 76 ( FIG. 6A ) for removal of the ink cartridge 22 from the fixture 22 .
[0041] The invention is also adaptable to contoured or shaped filter elements 80 as shown in FIGS. 7-9 . With reference to FIG. 7 , the filter 80 has a concave shape extending down into the filter tower 30 . In order to weld the filter 80 to the filter tower frame 30 , a transparent plate 82 having a convex portion 84 is used in the fixture 32 of the invention.
[0042] In FIG. 8 , filter 86 has a convex shape. Accordingly, transparent plate 88 , in this case, has a concave shape 90 as shown. Supports 92 may be provided in the filter tower 30 to support the shape of the filters 80 and 86 .
[0043] The invention is also adaptable to filters 94 having a complex shape by providing a transparent plate 96 as shown in FIGS. 9 and 10 having an opening 98 therein. A round opening 98 is shown in FIG. 10 , however any shape opening may be provided in the plate 96 provided there is a portion of the plate such as portion 100 that may be used to apply pressure to the filter 94 and filter tower frame 30 around the periphery of the frame 30 .
[0044] FIGS. 11 and 12 illustrate variations on the transparent plate and support legs that enable attaching a filter on an angle to an angled filter tower frame 110 . In FIG. 11 , the support legs 62 have substantially the same length. However, a transparent plate 112 thereof is thicker on end 114 compared to end 116 thereof. This enables the transparent plate 112 to apply substantially the same pressure around the entire periphery of the filter 28 and the filter tower frame 110 around the entire periphery of the filter tower frame during the welding process.
[0045] In FIG. 12 , a transparent plate 118 has the same thickness from end 120 to end 122 . However, support leg 124 is made longer than support leg 126 to enable the transparent plate to apply substantially the same pressure to the filter 28 and to the filter tower frame 110 around the entire periphery of the filter tower frame 110 during the welding process.
[0046] The apparatus of the invention as described above may also be adaptable to other laser welding techniques. Such techniques include, but are not limited to, contour laser welding, mask laser welding, quasi-simultaneous laser welding and the like.
[0047] Contour laser welding uses a laser light source and moves the part under the laser beam or moves the laser beam over the part, typically using an X,Y table. The laser beam typically travels around the weld area once or only a few times to complete the welding process.
[0048] Mask laser welding uses a laser light source that irradiates a linear section at a time. The mask is placed between the laser light source and the part to be welded. Then the laser beam or the part and mask combination are moved to sweep the laser beam across the mask and through the mask to the part being welded. Quasi-simultaneous laser welding uses a laser beam reflected off of movable mirrors such as those on a galvanometer head. The mirrors typically move very fast causing the laser beam to scan around the surface of the part to be welded at a rate of about 1 to about 10 meters/sec. This method heats the welding surface by quickly scanning an intense laser beam around the area to be welded. Accordingly, the laser beam scans around the part many times, from a few to thousands of passes, during the welding process. In yet another embodiment, simultaneous welding may also be used with the apparatus of the present invention. Simultaneous laser welding irradiates all of the weld area at the same time. Diode laser stacks can be placed directly above the weld area. Alternatively a diode laser, Nd:YAG laser, or some other laser can be used with optical fibers or some other light transmission media to direct the laser beam to the weld area.
[0049] The foregoing description of certain exemplary embodiments of the present invention has been provided for purposes of illustration only, and it is understood that numerous modifications, alterations, substitutions, or changes may be made in and to the illustrated embodiments without departing from the spirit and scope of the invention.
|
An apparatus for a laser transmission welding process for attaching a synthetic filter material to a filter tower frame in an ink jet printer cartridge. The apparatus includes a laser beam source and a filter clamping fixture containing a base, slide rods attached on first ends thereof to the base, an optics support plate attached to second ends of the slide rods, a movable platform for holding an ink cartridge slidably disposed on the slide rods between the base and the optics support plate, a platform moving device for translating the platform to and from a laser welding position, a laser beam transparent plate suspended by support legs from the optics support plate to a position between the movable platform and the optics support plate. The apparatus greatly improves synthetic filter attachment to a filter tower frame in an ink cartridge.
| 1
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 61/216,383, filed May 14, 2009, which is hereby incorporated by reference herein in its entirety.
TECHNICAL FIELD
[0002] The disclosed subject matter relates to systems, methods, and media for presenting panel-based electronic documents.
BACKGROUND
[0003] With the continued proliferation of portable electronic devices, there is a continued growth in the demand for mechanisms to view electronic documents, such as books, newspapers, magazines, comic books, etc.
[0004] Certain forms of electronic documents, such as comic books, include content in a layout that has multiple panels of content for each page. For example, with comic books, a top-left-most panel on a page may represent a first panel for the page, and the bottom-right-most panel of the page may represent a last panel for the page. By viewing and reading these panels from the top-left toward the bottom-right, a reader can observe a time-sequence of events in the comic books story line.
[0005] Current electronic document reading mechanisms do not adequately facilitate reading of such panel-based electronic documents, and therefore new mechanisms for presenting such electronic documents are desirable.
SUMMARY
[0006] Systems, methods, and media for presenting panel-based electronic documents are provided. In accordance with some embodiments, systems for presenting panel-based electronic documents are provided, the systems comprising: at least one processor programmed to: receive an electronic document, a definition of a first panel on a page in the electronic document, and a definition of a second panel on the page in the electronic document; control a display of the first panel based on the definition of the first panel; and transition from the display of the first panel to a display of the second panel by re-scaling the display and panning from the first panel to the second panel.
[0007] In accordance with some embodiments, methods for presenting panel-based electronic documents are, provided, the methods comprising: receiving an electronic document, a definition of a first panel on a page in the electronic document, and a definition of a second panel on the page in the electronic document; controlling a display of the first panel based on the definition of the first panel; and transitioning from the display of the first panel to a display of the second panel by re-scaling the display and panning from the first panel to the second panel.
[0008] In accordance with some embodiments, computer-readable media containing computer-executable instructions that, when executed by a processor, cause the processor to perform a method for presenting panel based electronic documents, the method comprising: receiving an electronic document, a definition of a first panel on a page in the electronic document, and a definition of a second panel on the page in the electronic document; controlling a display of the first panel based on the definition of the first panel; and transitioning from the display of the first panel to a display of the second panel by re-scaling the display and panning from the first panel to the second panel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a diagram of hardware that can be used in some embodiments.
[0010] FIG. 2 is a diagram of a process for creating a definition file in accordance with some embodiments.
[0011] FIG. 3 is a diagram of an example of a definition file in accordance with some embodiments.
[0012] FIG. 4 is a diagram of an example of a title selection interface in accordance with some embodiments.
[0013] FIG. 5 is a diagram of another example of a title selection interface in accordance with some embodiments.
[0014] FIG. 6 is a diagram of an example of an introductory display in accordance with some embodiments.
[0015] FIG. 7 is a diagram of an example of a multi-panel display in accordance with some embodiments.
[0016] FIG. 8 is a diagram of an example of a panel with masking displayed in accordance with some embodiments.
[0017] FIG. 9 is a diagram of a process for rotating an image in response to a device rotating in accordance with some embodiments.
[0018] FIG. 10 is a diagram of an example of an inter-panel transition in accordance with some embodiments.
[0019] FIG. 11 is a diagram of another example of an inter-panel transition in accordance with some embodiments.
[0020] FIG. 12 is a diagram of yet another example of an inter-panel transition in accordance with some embodiments.
[0021] FIG. 13 is a diagram of a process for transitioning between panels in accordance with some embodiments.
[0022] FIG. 14 is a diagram of an example of a panel and two sub-panels in accordance with some embodiments.
DETAILED DESCRIPTION
[0023] In accordance with various embodiments, mechanisms for presenting panel-based electronic documents are provided. These mechanisms can be used in a variety of applications such as to allow for viewing and reading panel-based documents, such as comic books, on portable electronic devices, such as mobile phones, portable media players, e-readers, tablet computing devices, laptop computers, non-portable devices and computers, etc.
[0024] Turning to FIG. 1 , an example of hardware 100 that can be used in some embodiments is illustrated. As shown, hardware 100 includes content creator computers 102 , document processors 104 , storage 106 , a server 108 , a communication network 110 , reading devices 112 , 114 , and 116 (such as a laptop computer 112 , a tablet computing device 114 , and a handheld device 116 ), online retailer 118 , and a brick and mortar retailer 120 .
[0025] In some embodiments, a panel-based electronic document may first be created by content creators on content creator computers 102 or created on paper and then transferred to content creator computers 102 (e.g., by scanning the document). These documents may be provided on computers 102 in any suitable format, such as ADOBE PORTABLE DOCUMENT FORMAT (PDF), bitmap, JPEG, etc.
[0026] The document can then be transferred to a document processor 104 directly or via network 110 . Any suitable protocol for transferring the document can be used in some embodiments. For example, the document can be transferred using the TCP/IP protocol.
[0027] At the document processor 104 , the document can be processed to define various parts of the document as described further below in accordance with some embodiments. This can result in a definition file, such as an XML file, for the document being created in accordance with some embodiments.
[0028] The electronic document and/or the definition file can then be stored in storage 106 in some embodiments. Any suitable mechanism for storing the electronic document and/or the definition file can be used. For example, the electronic document and/or definition file can be stored in database (such as database hardware and/or software), a mass storage device (such as a disk drive, an optical drive, magnetic media, memory, etc.), etc.
[0029] Server 108 can then access the electronic document and/or definition file and make them accessible to users using reading devices 112 , 114 , and/or 116 via communication network 110 . Users can access the electronic documents and/or the definition file as described below in accordance with some embodiments.
[0030] Any suitable server 108 can be used in some embodiments. For example, server 108 can be an Internet server that can communicate with the reading devices and/or storage 106 .
[0031] Any suitable network and/or combination of networks may be used as network 110 in some embodiments. For example, network 110 may include the Internet, a wired network, a wireless network, a local area network, a wide area network, a telephone network, a cable network, a satellite network, a fiber optic network, etc. In some embodiments, network 110 can include any suitable equipment such as routers, firewalls, servers, proxy servers, gateways, etc.
[0032] Reading devices 112 , 114 , and 116 can be any suitable devices such as a laptop computer 112 , a tablet computing device 114 , and a handheld device 116 , mobile phones, portable media players, e-readers, tablet computing devices, laptop computers, non-portable devices and computers, etc.
[0033] As described below, in some embodiments, a user can use a reading device 112 , 114 , or 116 to purchase a paper copy of an electronic document. For example, a user can use the reading device to purchase a paper copy of an electronic comic book. This purchase can be facilitated in some embodiments via online retailer 118 and/or brick and mortar retailer 120 . Any suitable equipment, such as a Web server can be located at the retailer 118 and/or 120 .
[0034] Any suitable components in hardware 100 , such as content creator computers 102 , document processors 104 , storage 106 , server 108 , reading devices 112 , 114 , and 116 , online retailer 118 , and a brick and mortar retailer 120 , can be implemented in one or more general purpose devices such as a computer or a special purpose device such as a client, a server, etc. Any of these general or special purpose devices can include any suitable components such as a processor (which can be a microprocessor, digital signal processor, a controller, etc.), memory, communication interfaces, display controllers, input devices, etc., and can be configured to operate in response to software instructions consistent with the functionality described herein.
[0035] As mentioned above, in some embodiments, document processor 104 can be used to create a definition file for an electronic document. An example of a process 200 for creating a definition file that can be used in some embodiments is illustrated in FIG. 2 . An example of a definition file 300 , in XML format, that can be used in some embodiments is shown in FIG. 3 .
[0036] As can be seen from FIG. 2 , after process 200 begins at 202 , the process can receive an electronic document. The document can be received using any suitable mechanism. For example, the document can be received via network 110 from content creator computers 102 or directly from the content creator computers 102 .
[0037] Next, at 204 , process 200 can create book information for the definition file. For example, as shown in FIG. 3 at 302 , the book information can define a version, a title, and a background color for the book as well as a cover image. Any other suitable book information can additionally or alternatively be defined.
[0038] After defining the book information, process 200 can select the first page of the book at 208 . The first page of the book can be selected on any suitable basis. For example, the first book can be selected as the first page following the front cover in a corresponding paper form of the electronic book.
[0039] Page information for the selected page can next be created at 210 . For example, as shown in FIG. 3 at 304 , page information can define a page file for the page and an index file for the page. Any other suitable page information can additionally or alternatively be defined. The page information can also include panel information corresponding to the page (as shown in 306 of FIG. 3 ).
[0040] Next, at 212 , process 200 can select the first panel on the page. The first panel on the page can be selected on any suitable basis. For example, the first panel can be selected as the panel in the top-left-most position on the page.
[0041] At 214 , panel information for the selected panel can next be created. For example, as shown in FIG. 3 at 306 , the panel information can include a panel mask color, a panel origin (e.g., such as the upper, left corner of the panel), and a panel size (which can be specific in absolute terms (e.g., in number of pixels) or in relative terms (e.g., as a percentage of a page), for example). Any other suitable panel information can additionally or alternatively be defined. For example, one or more sound effects for a panel can be defined. Such sound effects could be played when the panel is displayed. As another example, a vibration option could be defined for a panel so that a reading device vibrates when a corresponding panel is displayed. As yet another example, a panel could be defined so that it is to appear as being shaking relative to a reading device when displayed.
[0042] Process 200 can next determine, at 216 , whether any sub-panels are to be included for the panel. Subpanels can be used, in some embodiments, for example, to enable a portion of a panel to be highlighted when the panel is displayed.
[0043] An example of subpanels 1400 is shown in FIG. 14 . As illustrated in panel 1402 , the panel can have two sub-panels—e.g., each an area within panel 1402 . As shown the panel and sub-panels can be used to show the entire panel or some sub-portion of the panel. For example, as illustrated in FIG. 14 , a panel may be used to show “Olivia” using 1404 . For dramatic affect, it may be desirable to highlight Olivia's face using 1406 or Olivia's eyes using 1408 .
[0044] If it is determined at 216 that one or more sub-panels are to be included, the sub-panel information can be created at 218 . This sub-panel information can include any suitable information, such as the information described above for a panel in connection with 214 .
[0045] After the sub-panel information has been created at 218 , or if it is determined that no sub-panel information is to be included, then process 200 can determine whether the selected panel is the last panel on the page at 220 . If the selected panel is determined to not be the last panel, then process 200 can select the next panel on the page (on any suitable basis) at 222 and loop back to 214 .
[0046] Otherwise, if the selected panel is determined to be the last panel on the page, then, at 224 , process 200 can determine whether the selected page is the last page in the book. If it is determined that the selected page is not the last page, then process 200 can select the next page (on any suitable basis) at 226 and loop back to 210 .
[0047] Otherwise, if the selected page is determined to be the last page in the book, then, at 228 , process 200 can store the information. The information can be stored in any suitable manner, such as by writing the information to an XML file (e.g., as illustrated in FIG. 3 ) and saving it to storage 106 of FIG. 1 . Once the information has been stored, process 200 can end at 230 .
[0048] The creation of a definition file for an electronic document could be performed based on manual input or fully automatically in some embodiments. For example, the definition of a panel could include receiving a user click on an origin for an electronic document's panel and a dragging of a rectangle around the panel. As another example, the border of a panel could be determined by automatically detecting the edges of a panel and creating a shape around the panel and/or finding the best fit for a rectangle around the panel.
[0049] In some embodiments, rather than have rectangular (or square) shapes as described herein, panels could be defined as having any suitable shape. Such panels could be defined using vectors, using bitmaps, using combinations of one or more geometric shapes, etc.
[0050] Turning to FIG. 4 , an example of a user interface 400 for selecting an electronic document to be displayed in accordance with some embodiments is shown. As illustrated, this interface may include one or more titles 402 that a user can select for viewing. In some embodiments, after the user has selected a title, the user may be prompted for payment information, or pre-stored payment information may be accessed so that a payment for the title can be effected using the information.
[0051] Another example of a user interface 500 for selecting an electronic document to be displayed in accordance with some embodiments is shown in FIG. 5 . As illustrated, the interface can include a carousel of title 502 that can be quickly scrolled by user, and individual titles 504 that a user can select for purchase and/or viewing.
[0052] Once a user has selected a title for viewing (perhaps after purchasing the title), an introductory panel 600 for the title can be displayed as illustrated in FIG. 6 . Any suitable introductory panel can be displayed and such panels can (and likely will) vary greatly from title to title.
[0053] Next, in some embodiments, a multi-panel page 700 may be displayed as shown in FIG. 7 . This page may present multiple panels simultaneously so that a user can experience a similar feel to seeing a first page of a paper book when the previous page is turned. In some embodiments, a multi-panel display of a page when the first panel on the page is to be displayed can be disabled when desired.
[0054] As shown in display 800 of FIG. 8 , when a panel 802 is to displayed (e.g., after a multi-panel page has been displayed), the displayed panel can include masking 804 to obscure adjacent panels of the corresponding page. This masking can be in a color specified in the definition file. For example, the masking color can be defined for a specific panel, for a page, or as a default for a book. In some embodiments, the mask can be a given level of transparency, can have a pattern, can disabled, and/or have any other suitable characteristic. The characteristics of the mask can be defined based on definitions of default mask characteristics at the book, page, panel, and/or sub-panel level.
[0055] As shown in series 900 of FIG. 9 , in some embodiments, when a user rotates a compatible reading device, the orientation of the display can be adjusted to compensate. This may be desirable, for example, when a panel is best viewed in a landscape orientation and the user is holding a reading device in a portrait orientation. Thus, for example, as shown in FIG. 9 , when a user rotates a reading device counter-clock wise at 902 , a displayed image can automatically rotate clockwise in the device at 904 and scale to fit the new display orientation at 906 . In some embodiments, a rotation of a panel being displayed can be performed even when the reading device has not been rotated.
[0056] In some embodiments, after a user has viewed a panel, the user may initiate a transition to a new panel as shown, for example, by series 1000 of FIG. 10 . As illustrated, at 1002 , the user may tap on the displayed panel (or take any other suitable action). Next, at 1004 , the display can scale to the new panel size and then begin to pan to the new panel on the corresponding page. As the panning progresses, a remnant of one or more adjacent panels may be visible prior to the panel being finally displayed as shown at 1006 . Finally, after the transition is complete at 1008 , the panel can be displayed with any specified masking, such as illustrated in connection with FIG. 8 .
[0057] FIG. 11 illustrates another example of a series 1100 showing a panel transition in accordance with some embodiments. As show, after a user taps a panel at 1102 , the panel scales to the new panel and pans toward the right on the page to shown the new panel at 1104 and then 1106 .
[0058] Yet another example of a transition between panels is shown in series 1200 of FIG. 12 . As can be seen, this transition is between two panels diagonally located with respect to each other. After a user taps on a panel at 1202 , the transition scales and pans between the beginning panel and the ending panel at 1204 , 1206 , and 1208 . In some embodiments, the panning can occur along a line connecting the centers of the beginning panel and the ending panel.
[0059] Turning to FIG. 13 , a process 1300 for transitioning between panels in accordance with some embodiments is shown. As illustrated, after process 1300 begins at 1302 , a tap, or any other user indication, is received at 1304 . This tap (or other user indication) can be received in any suitable manner. For example, with a touch screen reading device, the tap can be received in response to a user touching the screen of the reading device. As another example, with a reading device that includes a mouse or other pointing device, the tap can be received in response to the user click a button on the mouse or other pointing device.
[0060] Next, at 1306 , information for the next panel to be displayed can be accessed. This information can be accessed from any suitable source. For example, the information can be accessed from a definition file, such as an XML file as illustrated in FIG. 3 .
[0061] The scale for the new panel can next be determined at 1308 . This display scale can be determined on any suitable basis. For example, the display scale can be determined based on the available display area on a screen, the orientation of the screen, making sure that the full content of a panel is displayed on the screen, balancing maximizing the percentage of the panel displayed against minimizing the amount of masking used, having a matte or margin of a certain amount of each side around the new panel, having a given amount of white space of one or more sides of the new panel, etc.
[0062] After the new scaling is determined, the displayed panel can be progressively re-sealed (e.g., by zooming to the new scale) at 1310 . Any suitable speed for re-scaling can be used in some embodiments. At 1312 , process 1300 can pan to the new panel based on the centers of the panels. Any suitable speed for panning can be use in some embodiments. In some embodiments, the re-scaling and panning in 1310 and 1312 can occur at the same time.
[0063] As the new panel becomes fully displayed, or after the new panel becomes fully displayed, the masking can be applied to adjacent panels that would be displayed due to the display size at 1314 . Once the masking is applied, process 1300 can then end at 1316 .
[0064] In some embodiments, the transition between some or all of the panels/sub-panels can be implemented without requiring user input. For example, in some embodiments, the transition between panels can occur without requiring that a user tap a panel. This can be implemented, for example, by waiting a specified and/or random amount of time before transition occurs.
[0065] In some embodiments, after the last panel on a page is displayed, a multi-panel view (e.g., as shown in FIG. 7 ) of the last panel and all of the panels of the page can be displayed. In this way, a user can see the entire page of panels upon completing viewing of the panels for a page. In order to display the multi-panel display of the page, a transition as described above may be made from the last panel to the entire page of panels, wherein the page of panels is treated as a panel for the purposes of re-scaling and panning. In some embodiments, the display of the multi-panel display after the last panel of a page is displayed can be disabled.
[0066] In some embodiments, any suitable computer readable media can be used for storing instructions for performing the processes described herein. For example, in some embodiments, computer readable media can be transitory or non-transitory. For example, non-transitory computer readable media can include media such as magnetic media (such as hard disks, floppy disks, etc.), optical media (such as compact discs, digital video discs, Blu-ray discs, etc.), semiconductor media (such as flash memory, electrically programmable read only memory (EPROM), electrically erasable programmable read only memory (EEPROM), etc.), any suitable media that is not fleeting or devoid of any semblance of permanence during transmission, and/or any suitable tangible media. As another example, transitory computer readable media can include signals on networks, in wires, conductors, optical fibers, circuits, any suitable media that is fleeting and devoid of any semblance of permanence during transmission, and/or any suitable intangible media.
[0067] Although the invention has been described and illustrated in the foregoing illustrative embodiments, it is understood that the present disclosure has been made only by way of example, and that numerous changes in the details of implementation of the invention can be made without departing from the spirit and scope of the invention, which is only limited by the claims which follow. Features of the disclosed embodiments can be combined and rearranged in various ways.
|
Systems, methods, and media for presenting panel-based electronic documents are provided. In accordance with some embodiments, systems for presenting panel-based electronic documents are provided, the systems comprising: at least one processor programmed to: receive an electronic document, a definition of a first panel on a page in the electronic document, and a definition of a second panel on the page in the electronic document; control a display of the first panel based on the definition of the first panel; and transition from the display of the first panel to a display of the second panel by re-scaling the display and panning from the first panel to the second panel.
| 6
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates, for example, to a semiconductor circuit used as a buffer circuit having the function of compensating a power source fluctuation and used for the amplification of a clock signal of a dynamic memory.
2. Description of the Prior Art
One of the conventional buffer circuits which amplifies an input clock signal φ 0 (hereinafter clock φ 0 ) (conversion of impedance) and supplies an output clock signal φ 1 (hereinafter clock φ 1 ) is constituted of MOS transistors Q1 through Q12 (Q9 is a MOS capacitor), as shown in FIG. 1. The input stage of the buffer circuit is a delay circuit constituted of the transistor Q1 through Q4. During the standby period the delay circuit holds the voltage of the node N2 which connects the source of transistor Q3 with the drain of transistor Q4 at a high level by using the input clock φ 0 and the inverted input clock signal φ 0 (hereinafter clock φ 0 ). The clock φ 0 is at a high level during the active period and is at a low level during the standby period. The clock φ 0 , because of the inverted polarity, is at a low level during the active period and is at a high level during the standby period. These clocks turn off the transistor Q1, turn on the transistors Q2 and Q3, hold the node N1 at a low level, which node N1 connects the source of the transistor Q1 with the drain of the transistor Q2 and the gate of the transistor Q4, turn off the transistor Q4, and charge the node N2 to the voltage of (Vcc-Vth) through the transistor Q3 during the standby period. The Vcc is the voltage of the high voltage side in the power source and is usually 5 volts, which is the standard value allowing for an error of ±10%. The Vth is a threshold value of the transistor. Since the gate of the transistor Q5 is connected to the power source Vcc, when the node N2 is charged to the voltage of (Vcc-Vth), the node N3 is charged to the same voltage. The node N3, which connects the transistor Q5 with the gate of transistor Q6, is the gate terminal of the transistor Q6 in the bootstrap circuit, including the transistors Q6 and Q7. By charging the node N3 to a high level during the standby period, the charged voltage of the node N3 drives, at a high speed, the output stage, including the transistor Q8 through Q12, at the next active period. Since the clock φ 0 is at the high level during the standby period, the transistor Q7 turns on, the node N4 which connects the source of transistor Q6 with the drain of the transistor Q7 and MOS capacitor Q9 and the gate of transistor Q11, turns to a low level, the transistors Q8 and Q11 turn off, the transistors Q10 and Q12 turn on, and the output clock φ 1 is at the low level, which is equal to the low level side of the power source Vss (usually ground voltage).
Entering in the active period the input clock φ 0 and φ 0 are inverted. In FIG. 2, waveforms of the operation are shown during the active period, and this example shows the case of the constant Vcc which is equal to 4.5 volts. Since, in this example, the voltage of the node N2 is equal to the voltage of the node N3 and the voltages of these nodes are (4.5 volts-Vth), when the clock φ 0 is changed from Vcc to Vss and the clock φ 0 is raised from Vss to Vcc, the voltage of the node 3 rises more than (Vcc+Vth) and the voltage to the node N4 is charged to the voltage of φ 0 , which is equal to Vcc, by the bootstrap effect, which is caused by the effects of the capacity between the gate and the drain of the transistor Q6 and between the gate and the source of the transistor Q6.
This results in the transistors Q8 and Q11 being turned on. At the same time, since the transistor Q1 turns on, the transistor Q2 turns off; the node N1 is charged up and the transistor Q4 turns on; then the voltage of the node N2 begins the decrease. Accordingly, the electric charges on the node N3 are deprived through the transistor Q5 and the voltage of the nodes N3 and N2 decreases to the voltage of Vss. When the voltage of the node N2 falls to a voltage of (Vss+Vth) the transistors Q10 and Q12 turn off and the voltage of the node N5 rises up to the voltage of Vcc. At this time, since the voltage of the node N4 is raised to more than (Vcc+Vth) through the capacitor Q9, the output clock φ 1 rises to the maximum voltage level Vcc.
The above-mentioned operation is carried out when no fluctuation of the power source occurs, while, as shown in FIG. 3, if the fluctuation of the power source occurs during the standby period, the output clock φ 1 is delayed, and delay of the output clock φ 1 creates a defect. In FIG. 3, the example is shown in which the voltage of the Vcc decreases from 5.5 volts (Vcc(U)) to 4.5 volts (Vcc(L)) during the standby period. The above-mentioned fluctuation occurs or the fluctuation of other devices connected to the power source occur because the electrical constitution of the constant voltage power supply is simplified, thereby causing a decrease in the production cost. During the standby period, the voltage of the clock φ 0 is low, the voltage of the clock φ 0 is high and the voltage of Vcc is 5.5 volts, causing both the nodes N2 and N3 to be charged up to the voltage of (5.5 volts-Vth). Further, if the voltage of Vcc decreases to the voltage of 4.5 volt during the standby period, the voltages of the nodes N2 and N3 (5.5 volts-Vth) do not change because there is no discharge path. The reason there is no discharge path is that the transistor Q4 holds off, and the Q 3 goes to off state because the gate voltage of Q 3 goes to 4.5 volts from 5.5 volts with the power source fluctuation. When the holding of the voltages of the nodes N2 and N3 is effected, the rising of the clock φ 1 is delayed. In order to raise the clock φ 1 , it is necessary that the transistors Q10 and Q12 are turned off; on the other hand it takes time for the voltage of the node N2 to fall to the low level at which the transistors Q10 and Q12 are turned off, because the voltage of the node N2 is 1 volt higher than the voltage of (4.5 volts-Vth) in FIG. 2. During the delay time when the voltage is falling from the node N2, the delay of the rising of the clock φ 1 occurs. In FIG. 3 the waveforms indicated by lines N2', N3', N5' and φ 1 ' show the passages of the voltage changes at the nodes N2, N3 and N5 and the voltage of the clock φ 1 without a power source fluctuation, as compared with the broken lines N2, N3, N5 and φ 1 , which show the passages of the voltage changes at the same portions when the fluctuation occurs in the power supply.
The present invention is proposed in order to minimize the above-mentioned problems.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a semiconductor circuit used as a buffer circuit in which the delay of the output clock caused by the fluctuation of the voltage of the power supply is improved and, thereby, the high speed access time is carried out by supplying a current leak circuit so that the charged voltages during a standby period are always maintained at the values corresponding to the voltage of the power source.
According to one aspect of the present invention, there is provided a semiconductor circuit used as a buffer circuit having an input stage circuit for receiving an input clock and an inverted input clock and having a node for providing an output, a bootstrap circuit, including a transistor, for receiving the output of said input stage circuit and for maintaining the gate voltage of the transistor at a high level during a standby period, and an output circuit including a transistor which is switched on and off by the output of the bootstrap circuit, for generating an output clock, the semiconductor circuit further comprising a current leak circuit for maintaining, during the standby period, the voltage of the node in the semiconductor circuit which is charged during the standby period at the value corresponding to the voltage of the power source.
According to another aspect of the present invention, there is provided a semiconductor circuit used as a buffer circuit, having an input stage delay circuit for receiving an input clock and an inverted input clock and including a node for providing an output, the node being charged during the standby period, a bootstrap circuit including a node, for receiving the output of the input stage delay circuit, the bootstrap circuit raising the voltage of the node with a bootstrap operation, and an output circuit for receiving the output of the bootstrap circuit for generating an output clock, the semiconductor circuit further comprising a current leak circuit connected between the node which connects the output of the input stage delay circuit with the input terminal of the bootstrap circuit and one of the output terminals of the power source, whereby, the voltage of the node in the semiconductor circuit which is charged during a standby period is always maintained during the standby period at the value corresponding to the voltage of the power source.
According to still another aspect of the present invention, there is provided a semiconductor circuit used as a buffer circuit having an input stage delay circuit for receiving an input clock and an inverted input clock and including a node for providing an output, the node being charged during a standby period, a bootstrap circuit including a node, for receiving the output of the input stage delay circuit, the bootstrap circuit raising the voltage of the node with a bootstrap operation, the bootstrap circuit including at least a first stage transistor and a second stage transistor, and an output circuit for receiving the output of the bootstrap circuit and for generating an output clock, the semiconductor circuit further comprising a current leak circuit connected between the node which connects the first stage transistor with the second stage transistor and one of the output terminals of the power source, whereby, the voltage of the node in the semiconductor circuit which is charged during the standby period is always maintained during the standby period at the value corresponding to the voltage of the power source.
According to still another aspect of the present invention, there is provided a semiconductor circuit used as a buffer circuit having an input stage delay circuit for receiving an input clock and an inverted input clock and including a node for providing an output, the node being charged during a standby period, a bootstrap circuit including a node, for receiving the output of the input stage delay circuit, the bootstrap circuit raising the voltage of the node with a bootstrap operation, the bootstrap circuit including at least a first transistor and a second transistor in a first stage and at least one transistor in a second stage, and an output circuit for receiving the output of the bootstrap circuit and for generating an output clock, the semiconductor circuit further comprising two current leak circuits, one of which connects a first node with one of the output terminals of the power source, which first node connects the first transistor and the second transistor in the first stage with the transistor in the second stage, and the other of which connects the second node with one of the output terminals of the power source, which second node connects the second transistor in the first stage with the output of the input stage delay circuit, whereby, the voltages of the nodes in the semiconductor circuit which are charged during a standby period are always maintained during the standby period at the value corresponding to the voltage of the power source.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a circuit diagram of an example of a conventional clock amplifier circuit;
FIG. 2 and FIG. 3 are waveform diagrams of the circuit of FIG. 1;
FIG. 4 shows a circuit diagram of a semiconductor circuit used as a buffer circuit according to a first embodiment of the present invention;
FIG. 5 is a waveform diagram of the circuit of FIG. 4;
FIG. 6 shows a circuit diagram of a semiconductor circuit used as a buffer circuit according to a second embodiment of the present invention;
FIG. 7 is a waveform diagram of the circuit of FIG. 6;
FIG. 8 shows a circuit diagram of another example of a conventional clock amplifier circuit;
FIG. 9 shows a circuit diagram of a semiconductor circuit used as a buffer circuit according to a third embodiment of the present invention;
FIG. 10 (a), (b) and (c) are circuit diagrams showing various modified current leak circuits used for embodiments of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 4, a circuit diagram of a semiconductor circuit used as a buffer circuit is shown, according to a first embodiment of the present invention, having a power source fluctuation compensating circuit (current leak circuit), as indicated by the reference mark X enclosed by broken line, which is not supplied in the FIG. 1. The circuit X consists of a series connection of an enhancement type MOS transistor Q13 for a leaking current turned on during a standby period and a depletion type MOS transistor Q14 for limiting the current; the circuit X is connected between the node N2 and the low voltage side Vss of the power source; and the node N2 is the connecting node between the transistor Q3, which turns on during the standby period and is used for charging, and the transistor Q4, which turns on during an active period and is used for discharging. In this example, although the "on" or "off" of the transistor Q13 is controlled by the clock φ 0 , another signal which corresponds to the clock φ 0 in the IC can be used instead of the clock φ 0 for this purpose. Besides, the transistor Q14 can be turned into other electric current control elements, for example, a resistor r1 (FIG. 10(a)); further, the transistor Q14 can be omitted, if the conductive resistance of the transistor Q13 can be made high by adjusting the width/length of the channel thereof (FIG. 10(b)). Further, instead of transistors Q13 and Q14, a resistor r2 can be used (FIG. 10(c)). Namely, the functions required of the circuit X are to allow a small amount of current to leak during the standby period and to cause the voltages of nodes N2 and N3 to fall to the voltage of (Vcc-Vth) at that time.
When the above-mentioned power source fluctuation compensating circuit X is attached, the nodes N2 and N3 are charged at the beginning of the standby period to the voltage of (5.5 volts-Vth) through the voltage of Vcc which is equal to 5.5 volts; then, when the voltage of Vcc falls to the voltage of 4.5 volts, the charge on the node N2 is discharged through the circuit X until the voltage of the node N2 falls to the voltage of (4.5 volts-Vth), as shown in FIG. 5. In the above description the voltage of the node N2 falls, more specifically, to the voltage of (4.5 volts-Vth-ΔV); however, the voltage drop ΔV is negligible, and is caused due to the resistance of the transistor Q3 when the transistor Q3 turns on. When the voltage of the node N2 falls to the voltage of (4.5 volts-Vth-ΔV), the transistor Q5 turns on, the charge on the node N3 flows to the node N2, and the voltage of the node N3 changes to be equal to the voltage of (4.5 volts- Vth-ΔV) which is equal to the voltage of the node N2. Therefore, the effect of the decrease of Vcc from the voltage of 5.5 volts to 4.5 volts, namely the delay of the rising of the clock φ 1 , does not appear during the active period, if the voltage of Vcc changes from the voltage of 5.5 volts to 4.5 volts during the standby period. Since the current which flows through the circuit X is of very little quantity, the charging of the node N2 takes place without obstacles. In the circuit in which the clock φ 0 synchronizes with the clock φ 0 and the falling of the clock φ 0 and the rising of the clock φ 1 occurs simultaneously, the transistor 13 is not necessary. Namely, since the nodes N2 and N3 are charged through the transistor Q3, if the circuit X consists of only a resistance for leaking, the voltages of the nodes N2 and N3 can be held to the voltage of (Vcc-Vth) at that time. However, usually the clock φ 0 does not synchronize with the clock φ 0 ; in some cases the clock φ 0 falls and after a while the clock φ 0 rises. In this case, if the circuit X consists of only resistance for leaking, the voltages of the nodes N2 and N3 fall excessively between the falling time of the clock φ 0 and the rising time of the clock φ 0 , and, accordingly, the transistor Q13 is necessary. In order to compare this with the case of having no current leak circuit X, the waveforms in the case of having no current leak circuit X are shown in FIG. 5 with broken lines.
In the above-mentioned embodiment, it is assumed that the voltage of Vth of transistor Q3 is equal to the voltage of Vth of transistor Q5. In the above assumption, if the voltage of Vth of transistor Q5 is higher than that of Q3 because of the non-uniformity of the transistor characteristics during the manufacturing process, the transistor Q5 remains off, but nevertheless the voltage of the node N2 falls to the voltage of (Vcc-Vth-ΔV); then, although the voltage of the node N2 falls as above described, the voltage of the node N3 cannot fall. If the voltage of the node N3 is high, as mentioned above, the voltage of the node N3 rises higher during the active period, and then the rising of the output clock φ 1 is delayed.
In FIG. 6, a semiconductor circuit used as a buffer circuit according to a second embodiment of the present invention is shown. In order to solve the above-mentioned problems, in the circuit in FIG. 6 the power source fluctuation compensating circuit (current leak circuit) is connected to the node N3. By using the power source fluctuation compensating circuit, the voltage of the node N3 can be the voltage of (Vcc-Vth).
In FIG. 7, the waveforms in operation of the circuit in FIG. 6 are shown. The voltage of the node N2 discharges through the transitor Q5 and the circuit X and falls to th voltage of (Vcc-Vth), the value of which is similar to the node N3. The waveforms in the circuit in FIG. 6, produced without the circuit X, are shown by the broken lines in FIG. 7, which can be compared with the solid lines which indicates the waveforms of the circuit in FIG. 6 produced with the circuit X. While, if the circuit X is connected at the node N3, as shown in the second embodiment, the electrostatic capacity of the node N3 increases and the bootstrap effect is interrupted at the rising time of the clock φ 0 and then the increase of the voltages of the nodes N3 and N4 is interrupted.
In FIG. 8, another example of the clock amplifier circuit using two transistors Q51 and Q52, instead of the transistor Q5 in FIG. 1. In this circuit, during the standby period, since the clock φ 0 is a high level, the transistor Q3 turns on, the voltage of the node N2 is the voltage of (Vcc-Vth), the transistor Q51 turns on and the voltage of the node N3 is the voltage of (Vcc-Vth). Then, since the voltage of the clock φ 0 is a low level, the transistor Q52 turns off and the node N2 is separated from the node N3. During the active period, since the voltage of the clock φ 0 is a high level, the transistor Q52 turns on and the circuit in FIG. 8 operates similarly as the circuit of FIG. 1. Also, in the case in which the voltage of Vcc changes before the active period, the voltages of the nodes N2 and N3 remain at an excessively high condition. In this circuitry, if the power source fluctuation compensating circuit is connected to either the node N2 or the node N3, since the transistor Q52 is off during the standby period, when the voltage of the power source changes, the voltage of the node to which the power source fluctuation compensating circuit is not supplied remains at a high voltage.
In order to solve the above-mentioned problem, a semiconductor circuit use as a buffer circuit is proposed, according to a third embodiment of the present invention, as shown in FIG. 9. In this circuit, two of the power source fluctuation compensating circuits X and X are connected between the node N2 and Vss and between the node N3 and Vss, respectively. Below, the cases are explained in which the voltage of the power source is fixed at 5.5 volts and in which the voltage of the power source rises up from 4.5 volts to 5.5 volts.
In the case in which the voltage of the power source is 5.5 volts, generally, at the high voltage of the power source, the mutual conductance gm increases; then the operating speed increases and there is no bad influence. Below, the explanation is given referring to FIG. 1. When the voltage of the power source Vcc is high, the voltages of the nodes N2 and N3 are high and the high level of the clock φ 0 rises higher; then the voltage of the node N1 rises higher and the gm of the transistor Q 4 is higher than the gm of the transistor Q 4 at the low voltage of Vcc. Since the gm of the transistor Q4 is high, the discharging speed on the nodes N2 and N3 is high.
Now the case will be described in which the voltage of the power source rises up from 4.5 volts to 5.5 volts. When the voltage of Vcc rises from 4.5 volts to 5.5 volts, the voltage of the clock φ 0 rises from 4.5 volts to 5.5 volts. The following facts are the reason why the voltage of the clock φ 0 changes from 4.5 volts to 5.5 volts. Namely, the clock φ 0 generates from the similar circuit as shown in FIG. 1, and when the voltage of Vcc is 4.5 volts and the voltage of the clock φ 1 is a high level (4.5 volts), the voltage of the node N4 is more than (Vcc+Vth) i.e. (4.5 volts+Vth). Also, the voltage of the node N5 is the voltage of Vcc. In this case, when the voltage of Vcc rises from 4.5 volts to 5.5 volts, the voltage of the node N5 rises from 4.5 volts to 5.5 volts through the transistor Q8, and since the voltage of the node N5 rises up the voltage of the node N4 through the transistor Q9, though the voltage of Vcc rises up to 5.5 volts, the voltage of node N4 rises to the voltage of more than the voltage of (Vcc+Vth), i.e. (5.5 volts+Vth), and the voltage of the clock φ 1 rises to 5.5 volts.
After the voltage of Vcc rises from 4.5 volts to 5.5 volts, the voltage of the nodes N2 and N3 are equal to the voltage of the nodes when the voltage of Vcc is fixed at 5.5 volts; therefore, there is no delay at the operating time.
|
A semiconductor circuit used as a buffer circuit having an input stage circuit for receiving an input clock signal and an inverted input clock signal, a bootstrap circuit including a transistor for receiving the output of the input stage circuit and for maintaining the gate voltage of the transistor at a high level during the standby period, and an output circuit, including a transistor which is switched on and off by the output of the bootstrap circuit, for generating an output clock signal; the semiconductor circuit further comprising a current leak circuit for maintaining, during the standby period, the voltage of a point in the semiconductor circuit which is charged during the standby period at the value corresponding to the voltage of the power source, whereby the delay of the output clock signal, caused of the fluctuation by the voltage of the power supply during the standby period, is improved and then the high speed access time in the dynamic memory is carried out.
| 6
|
BACKGROUND OF THE INVENTION
The present invention is concerned generally with the production of brown coal and lignite and more particularly with separating sand from a mined brown coal or lignite material which contains sand.
The terms brown coal and lignite are used interchangeably in this specification, although modern research may indicate that there may be certain differences between brown coal and lignite, from certain points of view; accordingly, where one such term is used, it is also to be deemed to include the other such term.
Although, by virtue of its chemical composition, sand is entirely inert in its behaviour upon combustion of or in other operations involving transforming brown coal or lignite, and therefore does not cause any environmental pollution, it is at least desirable and generally virtually essential for it to be at least substantially removed from the brown coal or lignite, when the amount of sand exceeds a given proportion, as otherwise a considerable amount of wear will occur in boilers or other equipment in which the sand-bearing coal or lignite is for example converted into gas or into liquid or reacted in some other manner.
The occurrence of a certain content of sand in mined brown coal or lignite, which constitutes a nuisance, is frequently inevitable even when the brown coal or lignite beds or seams are free from sand inclusions. However, with the present-day extraction methods and equipment, it is often inevitable that sand-bearing strata are also removed when mining coal from the roof and/or floor of a seam; that sand mixes with the coal and thus results in the raw brown coal or lignite material which comes out of the mine having a certain sand content. The sand content may be so high under some circumstances as to give rise to the difficulties referred to above. A similar situation may also arise for example when a stratum of sand of low thickness or strength occurs between two directly adjoining seams, as in such cases the stratum of sand cannot generally be shored up in the mining operation, and the mined material will inevitably include even higher proportions of sand.
These difficulties, which will be seen to arise due to the very nature of the beds or deposits and/or the mining process, have already been encountered for some decades, so that the problem of separating sand from a mining run of brown coal or lignite is not a new one. Accordingly, various attempts have been made in the past to overcome this difficulty and to remove sand from mined brown coal or lignite, or at least reduce the proportion of sand in such material to such an extent that the sand remaining in the brown coal or lignite does not give rise to difficulties such as those outlined above when the brown coal or lignite is subsequently put to use, and in particular therefore does not cause a significant amount of wear.
The reason that the problem of separating sand from a sand-bearing brown coal or lignite mix has not hitherto found a generally applicable solution is more particularly that the expenditure involved in separating out the sand cannot be at a very high level, as otherwise it becomes uneconomical to use the brown coal or lignite. This is essentially because the heating value of the brown coal or lignite is low, at any rate in comparison with other fossile fuels.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a process for separating sand from a mined brown coal or lignite material containing sand.
Another object of the present invention is to provide a process for separating sand from brown coal or lignite, which can be carried into effect in an economical fashion.
A further object of the present invention is to provide such a process which does not require complicated and costly apparatus.
Yet another object of the present invention is to provide a process for separating sand from brown coal or lignite, which does not involve transferring the materials in question between a large number of different pieces of equipment.
A still further object of the present invention is to provide a process for separating sand from a mined mixture including sand and brown coal or lignite, which makes maximum use of the brown coal or lignite available in the material.
A yet further object of the present invention is to provide such a process which operates on the basis of a simple grain size separation action.
These and other objects are achieved by a process for separating sand from mined brown coal or lignite material containing sand, wherein the sand occurs predominantly or entirely in a particle or grain size range which covers only a part of the particle or grain size range in which the brown coal or lignite falls, with the grain size of the coarsest grains of sand being markedly below the grain size of the coarsest grains of the brown coal or lignite. The brown coal or lignite which is in the grain size range of between zero and at least the grain size corresponding to the maximum grain size of the sand to be removed is first removed from the material by at least one gaseous classifying operation. The remaining, coarse, material is then subjected to a sieving operation, the dividing or cut-off line in the sieving operation being in the region of the grain size of the coarsest grains of the sand to be removed.
In general terms, the process according to the present invention is based on the consideration that the sand present in the brown coal or lignite material is generally restricted to a given particle or grain size range so that, once the brown coal or lignite which is in and below that grain size range is removed, it is then possible to separate the coal and the sand by a grading or classifying operation, by making a suitable selection in respect of the position of the dividing line, so that sand forms the material which passes through the sieve and coal forms the material which passes over the sieve. When certain preconditions are observed in that operation, it is possible for the sand to be almost completely separated from the coal, although it will be appreciated that some incorrect grain sizes will inevitably occur, i.e. some material will be incorrectly graded by reference to grain size to the extent that is generally encountered in regard to any grading and gaseous classifying operations. The above-mentioned preconditions are met when the range of grain size of the sand is so narrow that coal of the grain size which corresponds to the coarsest grain size of the sand can still be removed by the gaseous classifying operation, without at the same time sand having the smallest grain size also being entrained with the coarsest coal grain by the classifying air flow; in other words, more or less complete removal of the coal grain size range in question in the air classifier is possible when coal in the grain size range of from zero up to the coarsest sand grain size does not belong to the same equal-settlement or equal-falling classes as the sand which is present in the coal. The conditions referred to above can be controlled within certain limits, for example by means of the moisture content of the coal in the material fed to the gaseous classifier. Thus, coal with a higher residual moisture content, that is to say, the moisture content which is still present in the coal after the coal had been subjected to a drying operation, will have a higher specific weight than otherwise corresponding coal but with a lower moisture content. In other words, the two kinds of coal, differing by virtue of their moisture contents, fall into different equal-falling classes. However, even when the above-mentioned condition is not met, that is to say, when the equal-falling classes in respect to brown coal or lignite on the one hand and sand on the other hand do not overlap, the process in accordance with the present invention can still be usefully employed as in any case a substantial proportion of the sand can be removed; the amount of residual sand remaining in the coal will substantially depend on the extent of overlapping between the above-mentioned classes and also the selected position of the respective dividing or cut-off lines. Reference may be made to the more particular example set out hereinafter, to illustrate this aspect:
The sand-bearing brown coal or lignite material which has been dried to give a residual water content of 6% is of a grain size range of from 0 to 1 mm. The sand contained therein is entirely or predominantly only in the grain size range of from 0.1 to 0.5 mm. If it is to be possible to separate the two components of the material from each other by a grading operation, the preceding gaseous classifying operation must be carried out in such a way that the residual material forming the coarse component resulting from the gaseous classifying operation has only one of its two components in the grain size range of from 0.1 to 0.5 mm. According to the invention, this is achieved by the brown coal or lignite which is in the grain size range of from 0.1 to 0.5 mm being removed from the mixed material by the above-mentioned gaseous classifying operation. This also has the necessary result that brown coal or lignite in the grain size range of from 0 to 0.1 mm, which is therefore below the above-mentioned range of from 0.1 to 0.5 mm, will also be removed as the air flow which is used for the gaseous classifying operation and which is so adjusted as to be capable of entraining a brown coal or lignite grain size of 0.5 mm at maximum will of course also entrain brown coal or lignite grains which are of smaller size. The criterion in regard to virtually complete removal of the coal in the grain size range of from 0 to 0.5 mm, while at the same time leaving the coarse component containing virtually all the sand which occurs in the grain size range of from 0.1 to 0.5 mm, is that the coal grain which is to be removed by the gaseous classifying operation, being of a maximum grain size of 0.5 mm, falls into a different equal-falling class from the smallest grain size of sand which occurs in the material fed to the gaseous classifying and which, in the example selected herein, is of a grain size of 0.1 mm. If the situation were different, if for example coal grain of 0.5 mm and sand grain of 0.1 mm fell into the same equal-falling class, the fraction of coal of from 0 to 0.5 mm, which would be removed by the gaseous classifying operation, would also contain the sand of a grain size of 0.1 mm. In such a case, it will depend on the respective circumstances involved whether it might be considered desirable for the dividing or cut-off line in the sifting operation to be lowered from the above-mentioned figure of 0.5 mm for example to 0.45 mm, in order thereby to avoid entraining the grains of sand having a grain size of 0.1 mm; it will be appreciated that, if that adjustment is made, the coarsest grains of sand of from 0.45 to 0.5 mm will remain in the coarse component forming the residual material. The choice to be made in regard to such adjustment will depend inter alia on the grain size range in which the larger proportion of sand occurs, that is to say, at 0.1 mm or between 0.45 and 0.5 mm.
Another possibility could involve even further reducing the water content of the coal so that the flow speed of the air would have to be reduced in order to give a dividing or cut-off line at 0.5 mm, with the result that, at that reduced flow speed, the smallest grains of sand, being of a grain size of 0.1 mm, are no longer entrained by the sifter air flow. Whether that is expedient or necessary will also depend on the respective circumstances, for example including the increased expenditure in regard to the drying operation, as it will be appreciated that the drying expenditure increases in an over-proportional manner, with decreasing residual moisture content.
Depending on the particular factors involved, it may be desirable for the location of the dividing line in the gaseous classifying operation to be such that it is directly above the maximum sand grain size. However, it may also be possible for the location of the dividing line in the gaseous classifying operation to be such that it occurs at a distance above the maximum sand grain size, for example at a grain size of 0.7 mm in the above-discussed example, whereby the proportion of defectively classifed grain will probably be reduced. It will be appreciated in this case also that this will generally only be desirable when the increased flow speed of classifying air, which is required for that purpose, does not result in the lower sand grain fractions also being removed with the coal fraction which is entrained by the classifier air flow.
In any case however, coal and sand can be separated after the gaseous classifying operation, using simple means, namely grading, as the above-mentioned dividing or cut-off line occurs in a range which is advantageous in regard to the sieving or screening operation. That would not be the case for example if the attempt were made to separate the fraction of from 0 to 0.1 mm grain size, which in the above-described example is assumed to be free of sand, from the mixture of sand and coal, by a sieving or screening operation.
For the purposes of reducing the proportion of wrongly gas classified grain, it would of course also be possible for the coarse component from the gaseous classifying operation to be subjected to a further sifting operation during the sieving or screening step. That also applies in regard to the material which passes through the sieve or screen and which may therefore also be subjected to a gaseous classifying operation, especially as it should be borne in mind that abrasion will often give rise to the formation of further brown coal or lignite which falls into the grain size range of from 0 to 0.5 mm, during the grading operation.
Conventional gaseous classifiers and sieving or screening equipment may be used for carrying out the gaseous classifying operation and the sieving operation. It has been found particularly advantageous to use the equipment referred to as stage sieves, wherein a plurality of sieves are arranged one above the other, and the angle of inclination of the individual sieves relative to the horizontal increases in a downward direction. Such sieve arrangements are commercially available under the name `Mogensen sizers`. These arrangements comprise throw sieves, the surfaces of which are progressively inclined in a downward direction and the sizes of the holes of which are reduced in a downward direction.
It may also be possible for the process to be carried into effect in such a manner that the material comprising the sand and the coal is fed to the screening or sieving means in its entirety, that is to say, without a preliminary gaseous classifying operation, with the air sifting operation being performed during or in conjunction with the sieving operation so that it might be said that the gaseous classifying operation is superimposed on the sieving operation. In this connection, it should be noted that, when using the conventional throw sieves referred to above, the material being sieved is also loosened up to a considerable degree during the sieving operation, and that loosening effect facilitiates the gaseous classifying operation. Accordingly, that would involve the sieving means being arranged within a housing which at the same time performs the function of a gaseous classifying housing, that is to say, it also serves to guide the air flow for producing the gaseous classifying effect. With this mode of operation also, the material which passes through at least the upper sieve element is sifted, although this did not just involve removing coal grain, which was produced by abrasion, below the dividing or cut-off line, but on the contrary also involved removing the coal grain which was still present in the feed material from the outset and which was below the respective dividing or cut-off line. In the above-described example, that line occurs at a grain size of 0.5 mm.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the flow diagram of an installation for separating sand from sand-bearing brown coal or lignite, and
FIG. 2 shows a view in longitudinal section through a combined apparatus for carrying out gaseous classifying and grading operations.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring firstly to FIG. 1, in the flow diagram shown therein, freshly mined raw coal material RK, the water content of which is typically between 50 and 65%, with grain sizes ranging from 0 to 60 mm, is fed to a grading device 10, the dividing or cut-off line of which occurs at 6 mm. The material which passes over the sieve or screen, in a grain size range of from 6 to 60 mm, referred to as the oversize grain and indicated at UK, is removed from the grading device 10 for further use. The material which passes through the sieve or screen, referred to as the undersize grain and indicated at UK, being of a grain size of from 0 to 6 mm, is passed into a high-speed drying device 12 in which it is dried to the respectively required residual moisture content, of for example 14%, or 6%, or a value therebetween. The action of the heat which is involved in the drying operation results in shrinkage of the grains and also causes them to break up so that for example when the material is dried to a residual moisture content of 14%, the grain size may still be from 0 to 4 mm, while when it is dried to a residual moisture content of 6%, the grain size may be for example from 0 to 1 mm. The result of such breaking up of the grains of the feed material, which occurs in particular in high-speed drying and which is also to be attributed to the fact that evaporation in the moisture, some of it bound in colloid form, occurs very quickly, and possibly explosively, is that the grains of sand are extensively detached from the coal and therefore no longer remain attached or combined therewith so that, although the two components of the material are still mixed together, the individual particles or grains thereof are generally not joined together. In this respect it is assumed that the grains of coal have the usual ash content and the usual ash constituents, which cannot be separated from the coal substance by gaseous classifying and grading operations.
Hereinafter, similarly to the example discussed above, it is assumed that the undersize grain UK which is subjected to the high-speed drying operation in the device 12 is dried to a residual moisture content of 6%, and the dried material is in a grain size range of from 0 to 1 mm, with the coal in a grain size range of from 0 to 1 mm, while the sand is entirely or predominantly only in the grain size range of from 0.1 to 0.5 mm, that is to say, it only covers a part of the brown coal or lignite grain size range of from 0 to 1 mm.
The material (dry brown coal or lignite), as indicated at TBK, leaving the high-speed drying device 12, is fed to an air or gas classifier 14 in which the material is graded or sized under the effect of forces due to gravity, using air or another gas as the separation medium. This operation is carried out under such conditions, in regard to equal-falling particles or classes, that, with the dividing or cut-off line in respect to the brown coal or lignite at 0.5 mm, the brown coal or lignite in the size range of from 0.5 to 1 mm and all the sand in the grain size range of from 0.1 to 0.5 mm remain in the coarse material from the classifier, whereas all the brown coal or lignite which is in the grain size range of from 0 to 0.5 mm is removed by the classifier air and forms the fine component as indicated at FG from the gaseous classifying operation. The fine component FG is then passed on to the purpose to which the sand-free coal is to be put. The coarse component CG which contains the brown coal or lignite or more than 0.5 mm in size and all the sand in the grain size range of from 0.1 to 0.5 mm is passed to a sieving or screening device 16, the dividing or cut-off line of which occurs at a grain size value of 0.5 mm. The individual sieve or screen elements or surfaces 18 are disposed one above the other at inclined angles relative to the horizontal, which progressively increase downwardly in the device 16. The material which passes over the sieving or screening device 16, as indicated at SU, contains the coal whereas the material which passes through the device 16, as at SD, is formed by sand which may still contain some residual coal which is to be attributed in particular to the effects of abrasion on the coal during the sieving operation. The coal forming the material SU which passes over the sieving device is added to the coal which has already been separated out in the gaseous classifier 14. The material SD which passes through the sieving device 16 is passed to a post-classifying gaseous classifier 19 in which any improperly graded grain, that is to say, any coal which is still to be found in the sand, is separated out, and added as fine component FG to the rest of the coal from which the sand has been removed. The coarse component GC which issues from the second gaseous classifier 19 is almost exclusively formed by sand which can be dumped, or used in some other manner.
FIG. 2 shows in detail features of an embodiment of apparatus for carrying out the gaseous classifying and grading operations, corresponding to the area indicated by the dash-dotted square in FIG. 1. The dried sand-bearing brown coal or lignite TBK is passed by way of a metering and feed roller 20 to an air or wind gaseous classifier 22 through which it passes under free-fall conditions. At its lower end, the gaseous classifier 22 is delimited by an oscillating conveyor channel 24 which receives the material passing through the gaseous classifier. While passing through the gaseous classifier 22, particles of coal in the grain size range of from 0 to 0.5 mm are entrained by a flow of air or other gas which flows through the gaseous classifier 22 in the opposite direction to the direction in which the material falls therethrough, and are passed with the air or gas through outlets 26 and 28 to a conduit 30 which communicates with a fine material separator or trap which is shown in the form of a cyclone separator 31.
The coarser coal fraction, in the range of from 0.5 to 1 mm, which has remained in the residual material representing the coarse component, and sand of a grain size of from 0.1 to 0.5 mm, pass on to the oscillating conveyor screens or sieves 32, of which only two are shown in the drawing, below the channel 24. The channel 24 and the screens or sieves 32 may be driven by suitable drive means such as electromagnetic vibrator means 34, excitation means 36 which operate on the principle of an unbalance arrangement, shakers or other devices which are not shown in the drawing. Material is transferred from the channel 24 to the sieves or screens 32 and from each sieve or screen to the sieve or screen disposed therebelow by a cascade-like flow, the discharge following a parabolic path which results in the material being repeatedly loosened up in its movement through the installation. That promotes the removal of fine grains of coal by means of dust removal apertures 42 and dust removal lances 44 which are disposed laterally and within the space or chamber 40 towards the bottom of the installation. The resulting air-coal mixture is also passed to the fine component separator 31 by way of the conduit 30. The coal, which is now at least substantially free of sand, is removed from the housing 48 enclosing the whole system, by way of the discharge means 46. The sand which is separated by settling leaves the housing 48 by way of a discharge means 50. The air or gas flow which is required for the gaseous classifying operation is produced by a fan 52, the outlet of which is as shown connected by way of a conduit 54 to the space enclosed by the housing 48. The fine-grain coal which is separated out in the separator 31 is removed from the system by way of a discharge means 55.
The arrangement of gaseous classifying and sieving or screening device or devices within a common housing 48 has the advantage of a simplified construction, especially as the gaseous classifying and sieving operations can be superimposed one upon the other, ie can be carried out virtually at the same time, and the material involved does not have to be transferred between a large number of pieces of equipment.
Advantageously, the arrangement uses oscillating conveyors and oscillating conveyor screens or sieves which have individual drive means and which are controllable in such a way that the inertial oscillating forces which are otherwise normally found in sieving or screening machines are reduced to a minimum.
It will be seen therefore that the above-described combination of steps permit sand to be economically removed from material containing sand and brown coal or lignite, to such a degree that that can be used in a normal manner, without the need to take special steps or precautions to permit such use.
It will be appreciated that the above-described process and apparatus were described by way of illustrative example only and that various other modifications and alterations may be made therein without thereby departing from the scope of the present invention.
|
In a process for separating sand from a brown coal or lignite material containing sand, wherein the sand is present entirely or predominantly in a grain size range covering only a part of the grain size range of the brown coal or lignite, with the grain size of the coarsest grains of the sand being markedly lower than the grain size of the coarsest coal grains, the coal in the grain size range between zero and at least the grain size corresponding to the maximum grain size of the sand is removed by a gaseous classifying operation, and the remaining material is subjected to a sieving or screening operation, the cut-off line of which is in the region of the grain size of the coarsest grains of the sand to be removed.
| 1
|
FIELD OF THE INVENTION
[0001] The present invention relates to lower-body undergarments for women to prevent staining and leaking during menstruation.
BACKGROUND OF THE INVENTION
[0002] During menstruation, women are concerned about staining their undergarments as well as leakage of menstrual flow and the subsequent staining of apparel and bedding (when sleeping) even when they are wearing a tampon, sanitary napkin, and/or other feminine hygiene device. Despite all of the improvements in feminine hygiene products including super absorbent tampons and longer, more absorbent maxipads with side flaps or “wings”, women still experience leakage and staining of their undergarments, apparel and bedding (when sleeping). Dealing with stains is frustrating and time-consuming because blood stains can be difficult to treat. In addition, when leaks occur and the staining becomes visible on clothing and/or bedsheets, women experience embarrassment. Even the possibility of such an embarrassing leakage and stain can cause women anxiety and worry.
[0003] Women sometimes inadequately attempt to deal with the problem (or the potential of this problem) of staining and leakage by wearing dark-colored underwear and dark-colored clothing so that any staining would not be readily detectable. However, doing so limits a woman's choice of underwear and clothing and does not prevent the actual staining and the discomfort from leakage.
[0004] At least one undergarment has been offered that requires that at least some part of the panty is black in color. For example, the Philpott patent (U.S. Pat. No. 5,944,708) discloses a protective menstrual panty which is comprised of a black LYCRA fabric. As mentioned, this color requirement limits a woman's choice of underwear and does not prevent the staining and discomfort from leakage.
[0005] Some undergarments have at least three layers of fibers. As can be seen in several patents (Kennedy (U.S. Pat. No. 3,613,687) and Lamb (U.S. Pat. No. 4,573,987)), one solution provides multi-layer reusable diapers and diaper-like garments. However, multiple layers of fabric feel bulky and diaper-like and therefore are inadequate to address the problem.
[0006] Other solutions provide a liquid absorbent layer next to the skin with no special treatment to release stains and a liquid repellent layer on the outside of the garment. Bonito (U.S. Pat. No. 4,718,902) and Feder (U.S. Pat. No. 6,782,557). The absorbent layer next to the skin absorbs fluids and stains, leading to permanent staining, and causing leakage to outer clothing.
[0007] Other solutions provide for waterproof layers made from plastic, non-breathable, non-stretchable, polyester or coated with a modified polyester urethane polymer. As disclosed in Branch (U.S. Pat. No. 4,813,950), Rainville-Lonn (U.S. Patent Application No. 2004/0230175), and Gold (U.S. Pat. No. 5,098,419), several undergarments have been described having layers made from plastic. However, these solutions can be uncomfortable.
[0008] Nozaki (U.S. Pat. No. 6,613,034) and Coates (patent application) describe a suspended sling with a lining pad and extension cloth for extra protection.
[0009] Women are also concerned about the odors that may accompany menstruation. Women have tried to deal with this problem by using feminine deodorants and scented pads and tampons. However, these products often have their own unique odors that are closely associated with those products, and some women do not like to smell like such products.
[0010] Accordingly, a primary object of the present invention is to provide an undergarment that uses a minimal number of layers of fabric.
[0011] Another object is to provide an undergarment that is stain repellant and/or contains stain release technology in that the material itself has stain repel, stain repel and release, and/or stain release properties.
[0012] Yet another object of the present invention is to provide an undergarment that looks natural and comfortable.
[0013] A further object of the present invention is to provide an undergarment that is made from gas permeable material, thus making it breathable.
[0014] Another object of the present invention is to provide an undergarment that is easy to use for the wearer.
[0015] Yet another object of the present invention is to provide an undergarment that is re-usable and machine washable.
[0016] A further object of the present invention is to provide an undergarment which will accept disposable panty shields or sanitary pads for menstruation.
[0017] To accomplish the above and related objects, this invention may be embodied in the form illustrated in the accompanying drawings. However, the drawings are illustrative only and changes may be made to the specific construction shown and described within the scope of the claims.
SUMMARY OF THE INVENTION
[0018] The present invention is directed to resolution of the problem of leakage and staining of undergarments and outerwear during menstruation as well as the problem of odors from menstrual flow. Other solutions have been offered, but none provide the unique combination of benefits offered by this invention.
[0019] Fabric used in this invention will be treated with chemical enhancements to make the fabric repel (or resist) stains, repel and release stains, and/or release stains. Such fabrics are also known as fabrics with soil-and stain-resistant finishes and soil release finishes.
[0020] This undergarment is intended for women of all ages from the start of menarche through menopause. The undergarment looks and feels like a standard underwear from the exterior and can be adapted for a variety of styles including, without limitation, bikinis, boy shorts, briefs, hip huggers and low-rise. The structure of the crotch area of this undergarment contains a border, preferably in the shape of a ruffle, which folds inward and/or outward providing extra protection from leakage and staining.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The above and other features, advantages, and objects of the invention may become more apparent when viewed in conjunction with the accompanying drawings that depict certain preferred embodiments of the invention.
[0022] FIG. 1 is a front view of a panty constructed in accordance with the invention with a ruffle-bordered interior panel extending partially up the back of the panty and in partial phantom outline;
[0023] FIG. 2 is a rear view, with the edges from the front of the panty partly in phantom outline, of the panty shown in FIG. 1 ;
[0024] FIG. 3 is a folded out view of an interior panel covering the crotch area with a ruffled border and extending partially up the backside of the panty shown in FIG. 1 ;
[0025] FIG. 4 is a front view of a panty constructed in accordance with the invention with a ruffle-bordered interior panel extending fully up the back of the panty and in partial phantom outline;
[0026] FIG. 5 is a rear view, with edges from the front of the panty partly in phantom outline, of the panty shown in FIG. 4 ; and
[0027] FIG. 6 is a folded out view of an interior panel covering the crotch area with a ruffle border and extending fully up the backside of the panty shown in FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
[0028] The present invention relates to an undergarment which is stain repellant and/or stain release. Such an undergarment is particularly suited for use by women during the menstrual cycle. In addition, other situations for men, women and children may be conducive of use of the stain repel and/or stain release undergarment of the present invention. As discussed in more detail hereinbelow, the undergarment may be of any suitable style, so long as all or part of the undergarment comprises a stain repel and/or stain release fabric. The undergarment may be single layer or multi-layer.
[0029] A variety of chemical processes are known to impart stain release and/or stain repel characteristics onto fabrics. Many such chemistries are known in the art of outerwear or carpeting but have not been used in connection with an undergarment as described herein. “Stain repel” and “stain resist” are two terms used in the art (used synonymously herein) to describe the characteristic of a fabric wherein liquids such as water and/or oils are prevented from penetrating the fabric, but instead bead up and roll off the fabric. This characteristic is referred to herein as “stain repel”. A second type of advantageous fabric treatment is a “stain release” treatment, which enhances the ability of a fabric to release stains during laundering. For a stain release finish, liquids may not bead up, but may soak into the fabric, only to be easily washed away.
[0030] One method for creating stain repel and/or stain release fabrics uses fluorochemical treatments, which can impart fabrics with stain repellent characteristics as well as stain release characteristics depending upon the particular treatment methods employed. Examples of such methods are incorporated by reference and can be found in McLarty, (U.S. Pat. No. 5,855,991), Huber (U.S. Pat. No. 5,284,902), and Dams (U.S. Pat. No. 5,276,175). Other stain repel finishing agents include: flourocarbons, fluorochemicals, pyridinum compounds, resins, silicone, triazine compounds, wax and wax-like derivatives. All of these treatment methods can be used for the panty of the invention and can be found for example in Vasquez (U.S. Pat. No. 7,097,785), Theoliere (U.S. Pat. No. 7,094,743), Bamabas (U.S. Pat. No. 7,012,053), Beck (U.S. Pat. No. 5,002,684), and Degenhardt (U.S. Pat. No. 5,009,882). These patent disclosures are incorporated herein, in toto, by reference.
[0031] Stain repellants may be used on a variety of fabrics for use in the present invention. These are chemical treatments that can be used on any preferred fabric, for example but not limited to cotton, cotton blends, bamboo, bamboo blends, synthetics (such as acetate, nylon (polyamide), olefins (polypropylene, polyethylene), polyester, and or spandex) and synthetic blends. The main advantage is that the fabrics resist soiling during use. When a leak occurs and is still fresh, it can be spot-cleaned easily, since the stain is confined to the surface rather than penetrating deep into the fabric. Such finishes may employ the use of a fluorochemical, either alone or in conjunction with an extender. Applying a stain repellent finish prevents liquids, including water and/or oils, from penetrating the fabric causing potential aqueous and oily stains to bead up and roll off. Test methods used for evaluation include Oil Repellency (AATCC 118) for oily stain resistance and the Isopropanol/Water Drop test for aqueous stain resistance.
[0032] Fluorochemical water/stain repellent finishes provide durable liquid repellence (water and oil) without compromising the natural feel of a fabric. With proper chemical treatment and selection of fabric construction, an undergarment of the present invention can be produced that provide a host of benefits to the wearer, such as staying clean longer and faster drying.
[0033] Stain repellent finishes are effective in resisting soil; however, if soil does penetrate the finish, it may be difficult to remove. To counteract this, there is available a fluorochemical finish that not only repels stains, but also promotes release of that stain during washing. One such treatment method known in the art is Dams (U.S. Pat. No. 5,276,175) which is incorporated by reference, in toto, for its teachings of soil repel and release methods. The repellency of this soil releasing fluorochemical treatment method is useful in the undergarment of the present invention. Applying a stain release finish enhances the ability of a fabric to release stains during laundering. For a release finish, liquids may not bead up, but may at least partially soak into the fabric. Soil Release test (AATCC 130) is used for evaluation.
[0034] Another approach to soil release treatment of fabrics for use in the instant invention is the use of selected acrylic polymers. Unlike the soil release fluorochemical finish, the acrylic soil release agents give no soil repellency. However, good soil release properties are obtained. To achieve outstanding soil release and some repellency, a blend of the fluorochemical and the acrylic soil release chemistries are often blended together. See, for example Dams (U.S. Pat. No. 5,276,175).
[0035] In a preferred embodiment of the present invention, the chemical barrier layer may be a polymer such as “Resists Spills” from Nano-Tex™ or “Repels and Releases Stains” from Nano-Tex™ or a similar product from 3M or DuPont or a stain release product. Examples of such treatment methods are described in Soane (U.S. Pat. No. 6,472,476), Linford (U.S. Pat. No. 6,544,594) and Soane (U.S. Pat. No. 6,607,994) and are incorporated in toto by reference for their treatment methods for such fabrics. Nanotechnology with respect to fabric, describes material so minute in size that is incorporated into fabrics to give properties such as wrinkle resistance for cotton, without affecting the fabric feel, breathability, or strength. Nano-pel™ specifically, which is manufactured by Nano-Tex™, confers repellency to water and oil spills, while keeping the original texture (softness in touch) and breathability.
[0036] In another embodiment of the invention, Nano-Tex Resist Spills™ fabric is used. Nano-Tex Resist Spills™ fabric resists stains by the use of “whiskers” aligned by proprietary “spines” designed to repel liquids, which are attached to the fibers utilizing molecular “hooks”. These whiskers and hooks are very small (i.e., no more than 1/1000 th the size of a cotton fiber). See www.Nano-Tex.com. Contrary to conventional repellent technologies which are more like a coating which wash or wear away over time, Nano-Tex Resists Spills™ fabrics achieve durability without sacrificing the natural texture and breathability of the fabric. Nano-Tex Resists Spills™ fabric protection has been designed as a superior repellant product. While repellency and stain release are on opposite ends of the spectrum in chemical formulation, the nature of the repellency gives the ability to resist stains. Nano-Tex Resists Spills™ fabrics focus on maximum repellency, while balancing the need for release and maintaining the natural texture and breathability of the fabric. Nano-Tex™ has established the performance specifications for the fabric based around repellant benefits. This Nano-Tex™ fabric is a chemical enhancement, attached at the molecular level to transform the fibers and is a preferred method of fabric treatment for the undergarment of the present invention.
[0037] Because the undergarment uses fabric with either stain repel, stain repel and release, and/or stain release only properties that will prevent stains from adhering to the fabric or that will release stains that do adhere, no part of the underwear needs to be black to disguise stains. In fact, the undergarment can be made using a wide variety of colors, embellishments, designs and cuts.
[0038] Also, part or all of the outer covering, interior panel and/or border of the undergarment can be made from a stain repel and/or stain release fabric that feels similar to untreated fabric. No part of the undergarment needs to be plastic or laminated.
[0039] The undergarment is composed of stain repel, stain repel and release, or stain release only fabric referred to as “stain repel and/or release” fabric. In the preferred embodiment of the invention, an interior panel of stain repel and/or release fabric covers the crotch area of the undergarment. Preferably, this panel or an additional panel(s) of stain repel and/or release fabric covers the seat of the undergarment and can extend up the back either partially or all the way up the backside to the top of the back of the undergarment. The same or another panel of this fabric with stain repel and/or release properties can cover no part, some or all of the front side of the undergarment. If leakage occurs from a tampon or sanitary napkin onto the panel or any part of the undergarment, the fabric can be wiped clean if the stain is fresh, or simply washed in the washing machine with no need for pre-treatment of stains.
[0040] To prevent leakage from the undergarment onto apparel, the panel of stain repel and/or release fabric may also contain a side border, preferably in a ruffled fashion, made of such treated fabric that will provide additional protection against leakage and help to keep the sanitary napkin in place. The border may be facing the interior part of the crotch area (as shown in FIG. 6 ) or may face away from the interior part towards the outside of the undergarment. The border may also may be short and extend straight up from the fabric panel at a right angle to the fabric panel. In yet another embodiment, the undergarment may have two borders, one facing inside the crotch area of the undergarment and another facing the outside.
[0041] Finally, the undergarment can consist, in whole or in part, of fabric that has also been treated to be antimicrobial.
[0042] FIGS. 1 through 6 illustrate various embodiments of the invention.
[0043] FIG. 1 depicts a front view of a women's undergarment constructed according to one embodiment of the invention. An elastic waistband [ 1 ] is sewn around the waist opening in the outer layer [ 2 ] of stain repel and/or stain release material from which the panty is generally constructed.
[0044] In one embodiment of the invention, an interior panel made from stain repel and/or release fabric [ 3 ] is fully or partially sewn into the crotch area and extends partially up the backside of the undergarment [ 4 ]. A border made from stain repel and/or release fabric [ 5 ] is attached to or extends from the interior panel. A phantom outline [ 6 ] indicates how the interior panel may extend across the entire backside of the undergarment.
[0045] FIG. 2 depicts a back view of the same undergarment shown in FIG. 1 . The edges of the front side of the undergarment are visible in phantom outline [ 7 ]. The interior panel made of stain repel and/or release fabric extends partially up the backside of the undergarment [ 8 ]. Following the outline of the interior panel, the border extends partially up the backside of the undergarment and over the top back of the panel to the other side. See FIG. 3 for a graphic representation of the interior panel that would be sewn, partially or fully into the panty.
[0046] FIG. 3 depicts one embodiment of an interior panel that provides partial coverage up the backside of the undergarment. The panel itself is composed of stain repel and/or release fabric [ 9 ]. The interior panel has additional stain repel and/or release fabric bordering the panel partially or fully. In this embodiment, the panel is bordered with ruffled stain repel and/or release fabric on the inside portions of the panel [ 10 ] and the back of the panel [ 11 ] but not in the front of the panel [ 12 ]. The border can either be partially or fully cut from the same piece of fabric as the interior panel or additional fabric stitched onto the interior panel. The border extends from the edges of the crotch area some distance into the crotch area, for example about 0.15-1.5 inches from the edges, preferably 0.5-1.5 centimeters from the edge. The extent to which the border extends into the crotch area may vary depending upon the manufacturer's preference, but the border is preferably large enough to catch fluids in that area of the panty, thereby preventing leakage. Alternatively the border may extend from the edges of the crotch area to some distance away from the crotch area; i.e., toward and into the leg opening. The border can be gathered or straight. In the illustrated embodiment of FIG. 3 , the border is gathered in a ruffled fashion with a purl edging [ 13 ]. The border functions to provide additional protection from leakage of any liquids that may accumulate in the crotch area. It is understood that the ruffled border may be fashioned in any alternative manner, so that its function is maintained. In addition, it is contemplated within the scope of the invention that additional borders may be added and may face the inside crotch area or may face outward into the leg opening or both.
[0047] FIG. 4 depicts a front view of yet another embodiment of the undergarment constructed according to the invention. An interior panel made from stain repel and/or release fabric [ 14 ] may be sewn or attached to the crotch area and may extend fully up the backside of the undergarment. A phantom outline [ 15 ] indicates how the interior panel may extend up the entire backside of the undergarment to the elastic waist band.
[0048] FIG. 5 depicts a back view of the same undergarment shown in FIG. 4 . The edges of the front side of the undergarment are visible in phantom outline [ 16 ]. The interior panel made of stain repel and/or release fabric extends fully up the backside of the undergarment. In this embodiment, the interior panel is stitched in place [ 17 ].
[0049] FIG. 6 depicts a further embodiment of the interior panel that provides full coverage of the backside of the undergarment and has a border in a ruffled fashion that extends along the sides of the interior panel except for the front edge.
[0050] This undergarment may be worn with a conventional tampon and/or sanitary pad and is specifically designed to prevent staining of the undergarment itself and to prevent leakage and subsequent staining of apparel and bedding (when the wearer is sleeping). If the undergarment becomes soiled and the stain is fresh, the wearer can simply wipe the undergarment with a paper towel and continue to wear the undergarment until the wearer has the opportunity to change her undergarment. To wash the undergarment, the wearer only needs to wash it in the washing machine with no-pretreatment required.
[0051] The above description of various embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive or limiting to the precise forms disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments discussed were chosen and described to provide illustrations and its practical application to thereby enable one of ordinary skill in the art to utilize the various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the system as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled.
|
An undergarment to be worn primarily by women during menstruation that resists staining of the undergarment itself and prevents leakage of menstrual flow to outer garments. The outer covering of the undergarment with a waist portion and a pair of leg openings is composed of fabric to make the fabric repel stains, repel and release stains, or absorb and then release stains. A panel of fabric treated to make the fabric repel stains, repel and release stains, or absorb and then release stains covers the crotch area and may extend up the front and/or back of the undergarment. Fabric on each side of the panel, also made of fabric treated to make the fabric repel stains, repel and release stains, or absorb and then release stains, provides additional protection to prevent leakage. In addition, in the preferred embodiment, the undergarment will have antimicrobial properties. This undergarment is intended to be worn in lieu of a regular undergarment and with a tampon, sanitary napkin and/or other personal hygiene device.
| 0
|
BACKGROUND
[0001] 1. Field of Invention
[0002] This invention relates to portable massive structures which are used for applications such as seawalls and highway barriers.
[0003] 2. Description of Prior Art
[0004] Barrier having substantial mass have a variety of uses.
[0005] Traffic barriers serve not only to guide motorists, but to protect construction crews from injury. Significant mass is desired in order to absorb the energy of an errant vehicle to protect both life and property. Massive barricades also control crowds, have various military uses, and protect embassies and other governmental structures from terrorist threats.
[0006] Massive seawalls protect coastal areas from the ravages of storms and are also constructed for flood control to prevent water damage in runoff areas such as riverlands.
[0007] Coastal areas are constantly being battered by waves. Not much can be done about the destructive waves of such occurrences hurricanes and earthquakes. However, seawalls, also known as breakwaters, have shown to be effective in reducing erosion and protecting shore property. They are massive structures which form a barrier with which waves collide and lose at least part of their destructive energy. By absorbing this energy, seawalls prevent waves from releasing that energy on more valuable property. Consequently, these energetic waves are not able to carry away as much sand from beach areas, thereby reducing erosional effects.
[0008] Although the underlying principles of wave processes are not fully understood, it is generally accepted that during periods of low energy wave action beaches tend to stabilize and even accrete. Higher energy waves drag sand offshore. Through placement of seawalls during periods of destructive wave activity, such as during storms and winter conditions in general, it is suggested herein that erosion of certain beach areas can be reduced or stopped.
[0009] Seawalls are also used to protect inland areas which are subject to flooding. They may be used to direct floodwaters away from critical areas. The use of sandbags is a common protective measure in areas which are prone to flooding. They may be regarded as temporary seawalls, which are used in emergencies and removed afterward. More permanent structures, such as levees, serve to protect by providing an unobstructed and less damaging path for water to flow.
[0010] Construction of massive temporary barriers, at present, is a difficult and time-consuming process, in most cases requiring heavy equipment and a considerable amount of labor. These structures are many times comprised of concrete forms which must be delivered to the site and positioned by heavy equipment. A need exists for a simple method to construct a temporary barrier which has substantial mass, is portable, requires minimal storage space, is inexpensive, and does not require heavy equipment It is proposed herein that the instant invention fulfills all these necessities.
[0011] A novel method presented herein for building massive seawalls involves creation of modules which hold dense material available at the site of construction, such as sand and gravel. A module is transported in a separated or folded condition, and thereafter assembled and connected into a modular structure in a manner such that dense fill material may be easily loaded into the module and thereafter the module may be firmly closed. A module is constructed of separate connected panels which are made of a lightweight but durable material such as plastic or wood. Even large modules may be handled by workmen and fill material may be loaded manually or by utilizing light equipment. A multiplicity of modules of the instant invention may be placed in a linear manner forming a continuous massive wall in relatively little time. Since a module is not watertight, water may enter. This actually will temporarily increase the density of most fill material, since it tends to fill voids and the crevices between solid particles. This increased density weighs the module down even more securely. Of course, some outward seepage does occur, and some fill material will be lost. This seepage is insignificant, since minimal losses occur over short time periods, refill holes are designed so lost fill material may be replaced, and optional impervious insert bags or liners can be added to reduce losses. Prior art U.S. Pat. No. 4,784,520 teaches a substantially prismatic closed container which may be filled with liquid through a fill hole. Because it is not foldable, this prior art requires more storage and transport space, and is bulky when carrying. Additionally, the density of the fill material, mostly water, allows for a less massive structure than the instant invention, rendering it less likely to withstand energetic forces. Since the modules of prior art U.S. Pat. No. 4,784,520 and others have a specific gravity closely approximating that of water, they will nearly float when inundated. The invention presented herein is substantially filled with a high density material and therefore is less buoyant when immersed and able to resist movement when impacted by waves or other external forces. Also, the enclosed massive fill material consists of more solid matter, provides substantial resistive strength and therefore prevents damage and maintains the shape of the module.
[0012] Most prior art regarding seawalls presented herein fail to have the advantage of portability associated with the instant invention. The proposed device makes it possible to erect protection against water in a short period of time, and remove it quickly thereafter. None of the prior art describes this capability. A seawall module utilizes material found near the construction site to provide needed mass, although fill material may be transported if necessary. A module partially filled with sand or gravel approximates the resistive characteristics of an equivalent structure comprised substantially of concrete.
[0013] Although some of the referenced prior arts are portable and may be effective in certain highway guidance applications, their designs fall short of providing the mass, stability, strength and durability of the instant invention, The ability of the prior art to impede the progress of a moving vehicle is minimal, This invention provides a greater degree of protection in these instances. Currently, drums full of water or sand are used for certain highway applications to disperse energy of vehicles which may collide with them. The instant invention provides his energy-dispersing feature, but it is simpler to store, transport, assemble, and disassemble.
[0014] By altering the dimensional characteristics of a module, such as increasing the base panel size or changing the angles of the panels with respect to each other, factors such as stability, verticality and height may be varied. Many foldable designs are possible, only some of which are described herein. A more complete description of the invention follows, which will describe alternatives and obvious advantages of the device.
OBJECTS AND ADVANTAGES
[0015] Several objects and advantages of the present invention are.
[0016] (a) to provide an effective barrier for protection from moving objects and wave action;
[0017] (b) to provide an easily constructible barrier;
[0018] (c) to provide an inexpensive massive barrier utilizing materials from nearby areas
[0019] (d) to provide a barrier which may be constructed or removed in a relatively short period of time;
[0020] (e) to provide a barrier which does not require the use of heavy equipment for construction
[0021] (f) to provide a barrier which is foldable or stackable into a compact configuration so that a minimal space is occupied for storage and transport
[0022] (g) to provide a barrier which has significant mass
[0023] (h) to provide a massive barrier which may be used for protection in a variety of situations
DRAWING FIGURES
[0024] [0024]FIG. 1 illustrates three modules at different phases of construction
[0025] [0025]FIG. 2 illustrates a means for connecting panels
[0026] [0026]FIG. 3 illustrates an alternative means for panel connection
[0027] [0027]FIG. 4 illustrates an unfolded module
[0028] [0028]FIG. 5 illustrates a method of folding a module
[0029] [0029]FIG. 6 illustrates a folded module
[0030] [0030]FIG. 7 illustrates a hingeable connection of panels
[0031] [0031]FIG. 8 illustrates movement of hingeably connected panels
[0032] [0032]FIG. 9 illustrates a double-pinned hinge connection
[0033] [0033]FIG. 10 illustrates an unhinged embodiment of the invention
[0034] [0034]FIG. 11 illustrates a right angle module
[0035] [0035]FIG. 12 illustrates some alternative prismatic embodiments of the intention
SUMMARY
[0036] In accordance with the preset invention a substantially prim-shaped hollow module comprised of a multiplicity of lightweight separate or foldably connected panels is assembled and substantially filled with a dens fill material such as sand or gravel to form a massive barrier. After use, a module is disassembled and thereafter stackable or foldable into a compact storage and transporting configuration. Prior to completion of assembly into a hollow prismatic structure, dense fill material is loaded onto a base panel. A completed module forms a wide-based structure having stability, strength and mass enough to substantially withstand impacts, and which may be applied to such uses as seawalls for erosion and flood control and protective highway barriers.
DESCRIPTION
[0037] [0037]FIG. 1 illustrates a preferred embodiment of the present invention under construction having modules in the complete, partially complete, and unfolded conditions. Panels 1 . 2 , and 3 have identical rectangular dimensions in his embodiment and are firmly and hingeably communicated at edges 4 and 5 in a manner such that panels rotate freely with respect to each other. Panels are preferably made of a durable, lightweight material such as plastic, composite, or wood. Triangular panels 6 and 7 are firmly and hingeably communicated at edges 8 and 9 to panel 1 . Completed module 10 forms a prismatic hollow structure which is weighted down by fill material 11 also shown being manually loaded into partially completed module 12 . Prismatic is herein defined as a polyhedron having parallel congruent polygons as bases, in this case equilateral triangles, and parallelagrams as sides. Minor variations from this definition are envisioned, such as removing the congruency requirement, without varying greatly from the concept of the instant invention. In order to form a hollow prismatic structure, ties 13 are secured to corresponding ties 13 on adjacent panels which are not permanently in hinged communication. Loading is accomplished either by manual or motorized means since a partially completed module 12 offers large access at a convenient angle. After deposition of fill material 11 , panel 3 is rotated about hinged edge 5 and thereafter secured to panels 1 , 6 and 7 using ties 13 at corresponding locations along edges of adjacent panels. Tie 13 and enclosed fill material 11 maintain the shape of the module and provide strength. Fill material 11 is composed of gravel, sand, dirt, broken concrete or other dense material which has adequate specific gravity to weigh down a module. Loosely piled fill material 11 also naturally slopes at an angle which approximates the angle of the sides of a module, minimizing deforming of panels 2 and 3 from internal and external pressure. Since panels 6 and 7 are smaller, and since they often are in contact with adjacent modules to form a continuous banner, deforming pressure is less of a problem. An adequate supply of fill material 11 will usually be available near a job site, although it may be imported when necessary. A further use of ties 13 is to secure adjacent modules to each other to provide additional integrity to a series of modules which form a wall.
[0038] A completed module is not necessarily watertight, although it is constructed in a manner to impede loss of fill material. During usage, water accesses the module and actually increases the specific gravity of the enclosed fill material 11 thereby increasing stability. This is because water fills spaces in the module and gaps between particles of fill material 11 . Water accesses the module between panel edges and through replenishing aperture 14 . Small amounts of fill material 11 will be lost over time due to seepage, but these losses may be reduced by using impervious plastic liners or bags, and by shoveling or pouring additional amounts of fill material 11 through replenishing aperture 14 .
[0039] In FIG. 1 unhinged edges of panels are fastened using corresponding ties 13 . Other methods may be used, such as using pins, snaps or clamps. Any simple but strong method of attachment will maintain the shape of the structure. FIG. 2 illustrates the simplistic connecting means of FIG. 1 whereby adjacent panels may be effectively secured to each other by tying cords on corresponding panels. Cord 15 is threaded through grommets 16 and secured at positions near edges of panels. A simple not between corresponding cords on mateable edges provides sufficient strength to hold panels together during strong internal and external pressures. Additionally, cord 15 is long enough to further tie to corresponding cords on adjacent modules in order to form a continuously integral wall. Another example of an alternative connecting means for panels is illustrated in FIG. 3, wherein clip 17 is opened by compression of spring handle 18 and thereafter inserted ugh corresponding connecting openings on the panel then released. Various other connecting means are envisioned but not described herein.
[0040] An unfolded module of the present embodiment is illustrated in FIG. 4. A method by which a module may be folded and unfolded is presented in FIG. 5. Rectangular base panel 1 rotatably adjoins triangular panels 6 and 7 and rectangular panel 2 . Rectangular panel 2 hingeably adjoins rectangular panel 3 . E order to fold this embodiment into a compact size, panels 6 and 7 fold over panel 1 , thereafter panel 2 folds under panel 1 and panel 3 folds under panel 2 . A folded module is shown in FIG. 6. This folded configuration is secured by elastic 17 and minimizes space requirements since it is rectangular and stackable. Of course, this is only one embodiment, and a multiplicity of folding panes are possible by changing which panels are rotatably communicated.
[0041] Permanently hinged connection between such panels as panels 1 and 2 may be accomplished by a variety of methods, one of which is illustrated in FIG. 7. Clothlike strap 18 is firmly fastened to upper side of panel 1 by rivets 19 , and hereafter passed between panel 1 and panel 2 and then fatstened to lower side of panel 2 with rivets 19 . Adjacent strap 20 is fastened similarly to strap 18 , but in a reverse orientation wherein strap 20 is fasted to the upper side of panel 2 , passes between the panels and is thereafter fastened to the lower side of panel 1 . Additional straps are similarly fastened, each oriented oppositely to adjacent straps. FIG. 7 illustrates a hingeably rotatable connection composed of 5 straps, but using more or less is certainly an obvious
[0042] This embodiment of providing hinged connection between panels allows the panels to freely rotate substantially 3600 with respect to each other as illustrated in FIG. 8, having illustrations 8 a , 8 b , and 8 c . Proximal strap 21 and distal strap 22 are fastened to panels 1 and 2 in reverse orientation with respect to each other as previously described. As the joint is rotated from 8 a to 8 b to 8 c , it is seen that the panels are free to rotate until they lie flat against each other.
[0043] Panel corners 23 and 24 remain substantially in contact during rotation due to forces applied by the straps. A rotation in the opposite direction yields identical results, but corners 25 and 26 remain in contact. An alternative method of hinging panels is shown in FIG. 9, wherein a double-pinned hinge 27 is affixed to panel 1 and panel 2 and is rotatable 3600 . U-bolt 28 is of sufficient dimension to account for the width of the panels, preventing leverage damage when panels are flattened against each other.
[0044] Although a preferred embodiment of the instant invention as previously described is hingeably foldable, another embodiment is illustrated in FIG. 10 Three panels of the shape of separate rectangular panel 29 and two panels of the shape of separate triangular panel 30 are assembled and connected to form an unhinged module 31 *
[0045] Another embodiment of the instant invention is illustrated in FIG. 1, wherein right angle module 32 having vertical panel 33 presenting a surface which is perpendicular to base panel 34 . Right angle triangular panel 35 containing a 90° corner 36 is illustrated in FIG. 11 in tied communication with hypotenuse panel 37 . This right angle prismatic embodiment for the instant invention may especially be considered for highway use, wherein a protruding base toward traffic may be undesirable. It is obvious that the design of modules of the instant invention with regard to shape, size and hinging may be altered to fit a situation Some alternative prismatic embodiments for panel shapes are shown in FIG. 12. 12 a illustrates a wide-base, 12 b illustrates a narrow-base, 12 c illustrates a flat top right angle, 12 d illustrates a flat top wide base, and 12 e illustrates a hexagonal shape. Such a hexagonal shape may be an alternative method for reducing beach erosion, since it will have a tendency to roll, and therefore reduce destructive wave energy at locations which are most energetic. Although embodiments are envisioned having curved sides, such curvature will produce additional design considerations with respect to folding to manageable dimensions.
[0046] Further embodiments of the instant invention are envisioned, such as the following:
[0047] using panels for artwork, advertising, or warnings
[0048] coloring or marking the modules for safety, camouflage, or beautification
[0049] applying attachable elements such as flags, extensions, signs, or lights
[0050] using additional means to secure modules to the ground such as stakes or pins
[0051] using separate but attachable means, such as rods or ropes, to connect modules in assembly of a long continuous barrier
[0052] having a readily usable supply of fill material which may be easily transported for use in modules
[0053] adding attachable elements, such as rods, to increase stability of the module
[0054] Although the descriptions herein contain many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of the invention. Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.
|
Durable flat panels are connectable at their edges and are of appropriate shape and dimension to be quickly and simply assembled and secured into a closed hollow prismatic module configuration. A dense fill material is loaded onto the bottom panel prior to closure providing mass for strength and stability against impacts. The flat panels may be hingeably interconnected and foldable to optionally form a compact stackable configuration for storage and transport. A multiplicity of such modules may be positioned and connected to form a continuous massive wall for such uses as reducing damaging wave action, preventing beach erosion, directing water in flood areas, and providing highway barriers for guidance and safety.
| 4
|
BACKGROUND OF THE INVENTION
[0001] As the amount of information generated and stored in digital form has exploded over the last few years, demand for improved systems to display the information processed by new multimedia digital devices has become more critical. The most efficient way for humans to absorb vast amounts of information quickly is visual. 2-D displays have improved greatly in terms of price and performance over the last few years but in many applications the inherent 4-D nature of most data is shortchanged by the lack of a real third spatial dimension in the display device. The vast majority of 3-D devices require visual aids for the observer or complex mechanical motion in the display, and lack true 360* viewing capability for the audience. Several static, auto-stereoscopic volumetric display devices have been proposed and built over the last few decades but all of them have certain limitations in terms of spatial resolution, temporal resolution, viewing angle, color fidelity, ability to deal with occlusion and opacity, cost, and complexity of construction and operation (see Volumetric Display devices in Wikipedia).
[0002] The ability to display 3-D information accurately is becoming increasingly crucial in areas such as defense applications where the battlefield of the future is no longer bound by the 2-D limits of the surface of the earth but the 3-D of space. For example, pilots in (or remotely controlling) sophisticated aircrafts need to quickly assimilate the vast amount of data from advanced electronic monitor and command systems. The need for improved situation awareness encompasses informing the pilot of other aircrafts, ground threats and terrain in his area and their spatial relationship to his aircraft. A 3-D display capable of rapidly updating the data generated by computers and other electronic 3-D monitors would be ideally suited for this purpose. This technology could also provide realistic 3-D imagery of the cockpit's view for more effective laboratory flight simulators. A 3-D display could also support ground based applications including mobile and laboratory flight simulators, rapid cockpit prototyping, pilot-aiding artificial-intelligence knowledgebase development, unmanned aerial vehicles operations, and avionics development workstations.
[0003] Commercial demand for 3-D display capability is also expected to increase in the areas of radar and navigational displays, complex outputs from scientific and engineering simulations, medical and biotech imaging, robotic command, control and monitoring, entertainment and artistic applications, and numerous other needs.
[0004] We propose a novel 3-D volumetric display system called the video cube which is capable of 0.4-mm or better resolution over a very large format ( FIG. 1 ). The video cube consists of a gas-tight box filled with low pressure gas and a fine, 3-D grid of wires. The wires are energized by an array of medium voltage power sources and controlled by a 64-bit microprocessor with 128 GB of display buffer memory. This system permits true 3-D visualization from all angles and can be rapidly updated to display continuous moving images. The cost of the projected prototype system is high, but continued reduction in semiconductor component and plasma display technology costs should bring the cost of the video cube within reach of the commercial market by 2010.
DESCRIPTION OF THE INVENTION
C.1 Basic Concept
[0005] The video cube operates on the principle of photon emission from a moderate voltage discharge in a low pressure gas. It employs certain technologies already developed for particle physics detectors and gas discharge (plasma) displays.
[0006] The prototype video cube consists of a 225×225×225 mm air-tight glass cube (7 mm wall) filled with 600 Torr of Ne—Ar (0.1%) gas. Inside, an open cube structure, consisting of 4 inner walls made from 3 mm thick glass slabs with 100 μm diameter holes, spaced 400×800 μm apart is used as a frame to support a fine grid of wires. Each plane of wires consists of 100 μm diameter glass-coated tungsten wires, spaced 400 μm apart ( FIG. 2 ). Adjacent wire planes are strung perpendicular to one another. These wires are uniformly tensioned (2 N) and then epoxied to the glass frame.
[0007] Transparent external wire leads attached through the bottom and back of the cube may be used to supply power and signal to the inner wires. If a particular x i wire is energized to +V in the z i plane (anode), and a particular y i wire is energized to −V in the z i+1 plane (cathode) the large 2V potential drop across the 400 μm gap will create a glowing plasma cloud in the gas near the wires if a few seed electrons and ions are provided by cosmic rays, a nearby radioactive source, or a priming current.
C.2 Principle of Operation
[0008] The current will rise rapidly as a function of increasing voltage until the voltage reaches a plateau value known as the ignition voltage, V i ( FIG. 3 ). The height and the width of the plateau in the Townsend discharge region may be decreased by stepping up the incident radiation or injecting electrons from another source—a process known as “priming”. As the number of electrons increases, the current increases, and the space charge builds up near the cathode, the interelectrode voltage will decrease (B—C). The transition or subnormal glow state continues until a value of current density at the cathode which produces the most efficient ionization of gas molecules is achieved. The gas discharge will glow in the visible producing a bright point near the cathode—behavior characteristic of the normal glow region. For subsequent increases in current, the voltage increases slowly (maintaining voltage V m ), the current density remains constant, and the glow expands along the cathode wire. As soon as the discharge covers the entire cathode (abnormal glow region), the ionization efficiency begins to drop, and the voltage rises more rapidly with current. At very high currents the power dissipation and field become so great, and the temperature so high that thermionic emission and field emission become the dominant processes and an arc develops. When the potential drops below some extinction voltage V e , the glow will fade. To prevent the glow from spreading too far along the wires and the wires from sustaining too much sputtering damage, a series resistor or capacitor is used to limit the current (below D in FIG. 3 ) and the power.
[0009] A detailed examination of the glow discharge in the normal region of operation shows that there are two luminous regions separated from each other by a dark region called the Faraday dark space: the negative glow near the cathode but separated from it by the cathode dark space, and the positive column near the anode but separated from it by the anode dark space ( FIG. 4 ). As the interelectrode distance is reduced, the positive column reduces in length and eventually merges into the negative glow which generally dominates the emission. In this situation virtually all the potential drop occurs across the cathode dark space, and the electric field weakens through the negative glow region and falls to near zero outside this region. The ion and electron space charge density is also highest near the cathode.
[0010] The physics of the gas discharge reaction is quite complex. Important processes include excitation, metastable generation, ionization, and Penning ionization of atoms in the gas, and the ejection of electrons from the cathode surface by ions, metastable atoms, or photons. For illustrative purposes, consider a voltage applied across electrodes in a Ne—Ar gas mixture. Free electrons in the gas are accelerated by the electric field making many collisions with neon atoms. Since the neon atom does not have any allowable energy levels between 0 and 16.6 eV, most of these collisions will be elastic with no energy transfer. After many collisions, the electric field will have accelerated some of these electrons to energies greater than 16.6 eV which are then capable of exciting electrons in the neon atoms to higher energy levels. Electrons in these higher energy states typically have lifetimes of ˜10 −8 sec and radiate infrared, visible, and UV photons in the transitions back to the ground state ( FIG. 5 ).
[0000] Ne+e − Ne*+e −
[0000] Ne* Ne (or Ne*, or Ne m )+v
[0000] The dominant visible transitions are 2p electrons to 2s levels yielding photons with wavelengths near 600 nm (585 nm is brightest wavelength and correspond to the familiar orange neon glow). Electrons in the 2s 2 and 2s 4 states will relax quickly to the ground state with the emission of ˜74 nm UV photons. The brightness of the gas discharge depends on the power input and is typically of the order of 0.1-0.5 Im/W for neon based mixtures.
[0011] Electrons in 2/4 of the 2s states may not relax to the ground state with the emission of a photon and are therefore metastable, Ne m . Metastable atoms may remain as such for several microseconds until they are de-excited by a reaction with some other body. If they de-excite by collision with the walls, their energy is generally lost from the avalanche. They may also de-excite by collision with atoms which have ionization potentials lower than 16.6 eV. Argon (15.8 eV), krypton (14.0 eV) and xenon (12.1 eV) all satisfy this criterion. For example:
[0000] Ne m +A A + +e − +Ne
[0000] This reaction has a high probability, ˜3×10 3 times the probability of ionization in pure neon by the collision of metastables, and thus yield far more electrons and ions. This reaction is called Penning ionization and such multicomponent gases are called Penning mixtures.
[0012] When the free electrons gain more than 21.6 eV of energy they may ionize the neon atoms directly.
[0000] Ne+e − Ne + +2e −
[0000] The ions drift slowly toward the cathode and the electrons drift quickly toward the anode gaining more energy. The electrons can cause additional ionization resulting in an avalanche. As the avalanche progresses toward the anode, the number of ionizations increases exponentially with a multiplication factor (M), of several hundred possible.
[0000] M=γe αE/P
[0013] A number of reactions also occur at the surface of the cathode. Electron ejection from the cathode can be stimulated by collisions with positive ions, metastables, and photons. These electrons are critical to the discharge process since they initiate the gas reactions. The most important electron ejection mechanism is collisions with neon and argon ions which carry 21.6 and 15.8 eV of energy, respectively. The energy is more than enough to allow an electron to escape the work function potential of the cathode surface which is generally in the 3-20 eV range. Thus an ion collision has a high probability of ejecting an electron which coupled with the fact that every electron created in the avalanche generate an ion which drift to the cathode, constitute the main electron source for the avalanche. Photoemission may generate additional electrons since the UV photons have more than enough energy to knock out electrons. However, since these photons are emitted randomly, only a small fraction will intercept the cathode. Metastables can also eject electrons with a high probability but since they diffuse much more slowly and randomly, only a small fraction will impact the cathode.
[0014] Both the ignition and the maintaining potentials depend on the ionization of the gas and secondary effects at the cathode. It has been found by experiment that the ignition voltage depends on the product of the pressure P, and the interelectrode distance d (Murase et al. 1976),
[0000] V i =A ( Pd )/[log { B ( Pd )/log(1+1/γ)}],
[0000] where A and B are constants determined by the gas mixture, and γ is the secondary emission coefficient of the overcoat material. Curves of V i against Pd commonly show a minimum value ( FIG. 6 ). For example, Ne—Ar (0.1%) shows a broad minimum ignition voltage of ˜200 V near 30 Torr-cm using iron electrodes. For a planar electrode geometry this suggests that a pressure of 600 Torr should be used with an anode-to-cathode separation distance of 0.4 mm; for a wire geometry, the ignition voltage could be substantially lower since a low voltage can yield a very high field near a wire.
[0015] The perceived brightness of the display also depends on the dynamic behavior of the discharge since pulsed voltages are applied to the wires. The time for the avalanche to grow depends on the sum of a statistical and a formative delay time. The statistical delay time is due to the requirement for at least one electron to initiate the avalanche. In the absence of priming agents, an energetic cosmic ray may trigger the breakdown but this can take several minutes. This delay time may be reduced by increasing the priming current via radioactive source (eg. 85 Kr), pilot-cell, or self-priming techniques. Once the growth of the discharge has matured beyond the statistical regime, one must still wait for a finite time before the discharge reaches the desired current level and brightness. The current rise is an exponential function of time and the delay time is a strong function of the ignition voltage. The total delay time may range from 0.1 to 100 μs. The decay of the gas discharge after the applied voltage falls below V e is also important. The visible light or the afterglow decays within a few microseconds, but many of the other particles in the discharge lose energy much more slowly and determine the priming conditions for subsequent discharges. Metastables can be de-excited by the Penning process within a few microseconds. Ions and electrons in the weak field of a plasma will diffuse slowly to the electrodes and can take more than 5-50 μs to lose their energy. Since one electron can initiate a discharge, the impact of the residual charges on subsequent discharges can last for several milliseconds. This recovery time depends on the discharge current, the residual field strength, P/d, and the gas composition.
C.3 Electrical Design
[0016] The electrical system must provide the voltage to trigger the discharge, a viable scheme to limit the discharge current, the memory to refresh the display (although some modes of operation may not require this), and the microprocessor to control the wire addressing and interfacing to the information source. The electrical system contains the most expensive components of the proposed video cube design and may determine the future commercial viability of the device.
[0017] The basic requirement to limit the current in each discharge to avoid the negative glow from spreading along the cathode and significant damage to the electrode can be accomplished via two basic techniques: resistors and capacitors which define respectively, the dc and ac types of plasma displays ( FIG. 7 ). Resistors (˜100 kΩ) can be attached to each node of the matrix to limit the dc current flow. However, this technique is extremely expensive and awkward to implement. Alternatively, one resistor and voltage source may be attached to a line of nodes. This scheme requires that the voltage be pulsed and scanned. Pulse rise (˜2 μs) and self priming time (˜2 ms) considerations limit this technique to displays with <500 lines per axis. In addition, duty cycle and brightness considerations generally limit its practical use to <200 lines per axis.
[0018] AC displays use an internal dielectric layer to limit the current. The dielectric glass layer forms a small capacitor that is in series with every gas discharge. No external resistor is needed because the buildup of voltage across the dielectric limits the current. Because the dielectric glass is an excellent insulator, no dc current can flow, so that an ac voltage must be applied to maintain a discharge. The ac voltage and negative glow alternates between electrodes on each half cycle and sputtering damage to the cathode is less than for dc displays. Due to its memory capability (see below), the ac display does not need to be refreshed and for large formats is generally much brighter than dc displays.
[0019] When the total voltage applied across two wires at a node, exceeds the ignition voltage, a discharge current will begin to flow. This current will deposit charge on the glass dielectric walls which lowers the magnitude of the voltage across the gap sufficiently to extinguish the discharge. This charge on the wall is called wall charge and corresponds to a voltage component across the gas called the wall voltage V w . The combination of the wall voltage and the sustain voltage of the source yields the net voltage across the gap called the cell voltage.
[0000]
V
c
=V
s
+V
w
[0020] If a sustain voltage waveform of the proper amplitude and shape is applied to the wires, they will exhibit bi-stable memory. Typical sustain pulses have square symmetrical return-to-zero shapes, and widths of ˜10 μs at a frequency of 50 kHz ( FIG. 7 ). The zero-to-peak pulse amplitude is ˜100 volts. When a cell is on, it discharges and emits light whenever the sustain waveform first achieves a positive or a negative peak. When the wall voltage increases sufficiently that the net voltage drops below the extinction voltage, the discharge will die after a few microseconds. Now the residual wall voltage is of the opposite polarity so that when the sustain voltage is reversed, the high magnitude of V c will again ignite a discharge. In the off state, there are no discharges and the wall voltage remains at zero. In this case V c =V s with V s set sufficiently below the ignition voltage that no discharges will occur. Thus a node can be in either the discharging or non-discharging state with the same sustain voltage applied.
[0021] To excite the proper node or voxel in the video cube, one must introduce the appropriate address pulses needed to change the wall voltage and state of the node (FIG. 8 ). A separate voltage source is used to generate a write pulse of sufficient amplitude to initiate a discharge. This discharge will charge the walls of the wire and change V w from zero to the on-state level. A typical width of the write pulse is ˜5 μs. Similarly, an erase pulse may be sent to turn off the node. Like the write pulse, the amplitude and width of the erase pulse is selected so that only half the amount of wall voltage change occurs compared to a normal sustain discharge. The net write or erase voltage is the sum of voltages supplied by 2 coincident voltage pulses applied to the appropriate x, and y wire planes each of which carries half the voltage. A write/erase enable signal is used to cyclically select the appropriate z plane through a diode-resistor network 512 times every 16.6 ms permitting the x-y information to be updated for 32 μs each cycle.
[0022] The number of voltage drivers needed for a full matrix implementation of the 512 3 3-D display is 512×3=1536. A separate driver is used to supply address voltage for each x and y wire plane, and the 512 sustain voltages on each z plane. Each address driver need to supply ˜50 volts. Integrated circuit address driver packages can be obtained from semiconductor manufacturers such as Texas Instruments (TI). TI has a 40-pin dual-in-line package (SN 75500/1) capable of driving 32 display lines with up to 100 V pulses at currents up to 20 mA. CMOS shift registers and logic gates are included in each device to help interface the device to the controlling microprocessor. The video cube requires 48 of these chips. The sustain-voltage generator must be robust enough to rapidly charge and discharge the large capacitance of the wire planes and power the simultaneous discharging of a large number of nodes.
[0023] A 64-bit microprocessor (Intel Itanium 2) can be used to control the address voltage drivers. A 128 GB flash buffer memory can be used to store several minutes' worth of 512 3 =1.3×10 8 voxels of dynamic volumetric display.
C.4 Mechanical Design
[0024] We have considered two basic structural designs for the video cube corresponding to mechanically or electrically multiplexing a plane of information: a moving plane of wires, and a full cubic lattice of wires. A set of 3 20×20 cm plane of 512×512 wires set orthogonal to one another can be rotated fast enough (˜60 Hz—relying on the eye's persistence of vision) to produce flicker-free 3-D images ( FIG. 9 ). This would be similar to other swept-surface volumetric displays currently proposed and/or built. A microprocessor can be used to address the proper nodes in phase with the rotation. This alternative has the attraction of a simple structure and lower material cost. Connected to a 64-bit microprocessor with 128 GB of memory, the proper software/firmware instructions to address the 3-D image can be coded to synchronize the data with the rotation. Displaying the rotating plane of information to yield 3-D images can be thought of as the reverse of acquiring 3-D information with CAT planar scans in medical applications. Like other swept-plane volumetric displays it would have size, occlusion, and temporal resolution issues which can be better addressed with a static volumetric display.
[0025] Our preferred embodiment is a static volumetric display employing a full 3-D matrix of wires. Such a lattice structure should provide brighter, truer, and more stable dynamic images. The stationary structure should be more reliable, consume less power, and require less computing power and time to encode and address the voxels. This scheme does suffer from the disadvantage of requiring 50% more driver circuits to operate.
[0026] The prototype 3-D video cube has a simple 220×220×220×6 mm outer glass (soda lime silicate) vacuum-tight envelope. The internal structure is an open cube consisting of 4, 3-mm thick glass slabs fritted together. 100 μm diameter holes, spaced 0.4 mm×0.8 mm apart, are drilled into each slab before joining ( FIG. 10 ). Each of the 512 planes of wires consist of 80 μm diameter tungsten wires coated with 10 μm of solder glass dielectric material. 200 nm of MgO is used to overcoat the dielectric glass. The MgO has a high secondary emission coefficient which remains very stable with time. The wires are spaced 400 μm apart and attached to the glass frame with glass-to-metal seals. Adjacent wire planes (labeled x and y) are oriented orthogonal to one another and separated by 400 μm. This choice of dimensions leaves >99% of the volume transparent. A different choice of electrode geometry might be better to minimize the amount of backside emission from a solid object (the hidden surface or occlusion problem—analogous to the hidden line problem for 2-D display of 3-D objects which is solved with proper coding), but could also entail a tradeoff between mechanical stability and accuracy, gas mixture, and transparency. 512 wires with the same x coordinate are wired together, as are 512 wires with the same y coordinate, each to one of 1024 voltage driver circuit outside the glass envelope through the bottom side of the cube. Every wire on each z plane is wired to one of 512 diode-resistor switches outside the cube through the bottom side. After assembly and before sealing, the entire structure is evacuated and outgassed thoroughly under hard vacuum to reduce contaminants.
[0027] While the mechanical structure of the video cube is somewhat unusual, we are confident that it will work. Large-scale open-celled structures (Nolan, 1969) as well as wire electrodes have been used successfully in previous gas discharge displays. Similar wire plane structures have been built for photon and particle detection in square meter sizes that have met high alignment requirements and withstood severe environmental stresses.
C.5 Summary: Unique Aspects and Other Enhancements
[0028] The video cube possesses many of the same advantages that 2-D plasma displays have over other display systems: very strong electrical nonlinearity, discharge switching, intrinsic memory, long lifetime, good brightness and luminous efficiency, rugged and simple structure, high resolution and fidelity, large formats, and tolerance for high temperatures and stray magnetic fields. While the proposed video cube is quite similar to a 2-D gas-discharge display, the use of thin conductive wires in a 3-D grid rather than conductive strips on a bulky substrate permit a more compact and higher resolution true 3-D display with lower voltages and higher pressures. Construction and mechanical alignment should be no more difficult than conventional plasma displays. Most importantly, the video cube offers a unique and effective way to present dynamic, 3-D image information.
[0029] Future enhancements include improving the color fidelity and occlusion/opacity capability of the basic video cube. One design is use a close packed cubic array of coated gas-filled glass beads ( FIG. 11 ). A prototype geometry involves 400 μm diameter beads filled with 3 different mixtures of noble gases (e.g. Ne—Ar, Ne—Kr, and Ne—Xe) which glow at different colors. Adjusting the voltages at crossed wire points would excite different voxels to emit different colors which can be mixed to produce a spectrum of colors. A thin coating of an electrochromic (or liquid crystal material) on each glass bead surface can be electrically controlled to make the voxel more or less transparent. Inner glass beads corresponding to non-visible voxels can be made opaque with proper voltage-current setting between two crossed wires controlling that voxel. This will provide true color solid imaging permitting the video cube to replace conventional display systems in a wide range of applications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 . Schematic of the Video Cube comprised of a stack of alternating orthogonal thin wire planes enclosed in transparent air-tight glass cube containing a noble gas mixture.
[0031] FIG. 2 . Schematic of the wire grid geometry with one set of tungsten wires running along the x-axis and an adjacent set of wires running along the y-axis. When a pair of wires are energized +V in the x-direction and −V in the y-direction, the potential difference will cause a gas discharge glow to appear between the wires.
[0032] FIG. 3 . Graph of the current-voltage characteristic for a typical gas discharge.
[0033] FIG. 4 . Schematic of the potential, field and charge density distribution near the glow regions. In our compact wire geometry the positive column is actually not separated from the negative glow.
[0034] FIG. 5 . Energy level diagram for neon showing some of the major transitions.
[0035] FIG. 6 . Paschen curve showing the dependence of the breakdown/ignition voltage on the product of the gas pressure and the cathode-anode separation distance for several gases.
[0036] FIG. 7 . Schematic of the dc resistive and ac capacitive current limiting schemes
[0037] FIG. 8 . Schematic of the timing logic used to write and erase a cell. Voltage pulses for each of the x, y, and z wire planes are shown for a typical active and inactive cell.
[0038] FIG. 9 . A schematic of the rotating plasma panel that could produce a swept-plane volumetric 3-D display.
[0039] FIG. 10 A magnified view of a corner of the video cube shown in FIG. 1 detailing the wire glass frame structure inside the cubicle glass enclosure.
[0040] FIG. 11 A detailed schematic of an alternate embodiment of the video cube to provide improved color fidelity and occlusion/opacity capabilities. The same array of orthogonal planes of wires as described in FIG. 1 is filled with a closed packed cubic array of coated gas-filled glass beads. Each of 3 sets of beads contains a different mixture of noble gases with different glow discharge colors. Each glass bead is coated with an electrochromic or liquid crystal film to control transparency.
|
The present invention is a novel, high resolution, color, three-dimensional (3-D) volumetric display system for dynamic images—the video cube. The video cube consists of an air-tight glass cube filled with a gas mixture and multiple planes of thin wires arranged in alternating orthogonal layers. These wires may be set at voltage potentials capable of producing a glow discharge at the intersection of pairs of wires. Using a computer capable of storing dynamic image data and electronic controllers capable of energizing pairs of wires appropriately at the proper time 3-D dynamic images may be formed from multiple glows between excited wire pairs. The video cube may be used to display complex real-time information from computers and other digital processors with high accuracy for unlimited number of simultaneous unaided observers.
| 7
|
FIELD OF THE INVENTION
This is a continuation of application Ser. No. 08/254,900, filed Jun. 6, 1994, now abandoned.
The present invention relates generally to miniature surgical instruments and instrument systems, and, more particularly, to such instruments and systems as are used, e.g., in endoscopic surgery, including, forceps, graspers, needle holders, scissors, scalpels, trocars and punches.
BACKGROUND OF THE INVENTION
The present invention relates to micro-instruments, i.e., articulating hand held instruments used in micro-surgery and various types of surgical instruments, such as are used, e.g., in endoscopic surgery, including, e.g., as to endoscopy and other fields, forceps, graspers, needle holders, scissors and punches differentiated by their working tip designs, but using a common handle and tubular shafts, varying in length and/or diameter. The instruments can comprise scissors-handle-actuators, so-called cigar handle linear or rotary activators, or other actuators, with push or pull force application design modes.
The following discussion of the invention focuses on instruments required for endoscopic usage (minimally invasive procedures) and more particularly punches, scissors and graspers used in laparoscopic surgical procedures, and to other surgical instruments and non-surgical instruments.
Recent generations of enhanced miniaturization of endoscopic instruments have encountered the problem of being unable to reach certain areas because they were not bendable or flexible or did not articulate in a manner most useful for the surgeon. On current hand held medical instruments from the hand held portion to the distal end, the instruments are normally of a straight rigid design allowing the distal end to pass through a cannula to the work site.
In this field it is frequently difficult for the surgeon to obtain access to a particular portion of a body part due to the limitations of the instruments which are used. In an attempt to overcome this, a flexible forceps is disclosed in U.S. Pat. No. 3,895,636, which has a flexible shaft in the form of a thin solid rod of wire wound into the form of a hollow spring.
U.S. Pat. No. 5,209,747 discloses an adjustable angle medical forceps which has jaws mounted on a shaft and which shaft rotates about the main shaft so that the jaws can be rotated to be at different angles to the main rod.
U.S. Pat. No. 5,254,130 discloses a surgical device having a flexible end. However, such devices have not been adequate. It is a principal object of the invention to provide micro-instruments of the classes described above which have steerable distal effector ends to provide the surgeon with great flexibility in reaching body parts which are difficult to reach.
SUMMARY OF THE INVENTION
These and other objects are accomplished by a surgical instrument which has means for permitting steering of the end effector assembly. Once the distal end passes through the cannula the distal end may be moved radially away from a straight linear line in a steerable manner, controlled from the hand held portion of the instrument thereby allowing the distal end to operate in three dimensions as differentiated from the standard one dimension.
The mechanism is made of standard end effectors attached to an intermediate section which bends in a desired manner and which attaches the end effector to the handle and shaft sections of the instrument. The section which provides steering is constructed of a plurality of similar parts adjacent to one another and each of which has a specially shaped surface which allows the parts to be held together so that they are inclined with respect to each other thereby forming a curve in the section. Since the shaft on which these parts are connected can move into any angular position, the end effectors can be placed into any angular position once the instrument has been introduced into the patient's body. Wires which extend to the handle area control the inclining action of the parts. In the case of a biopsy, grasping jaws, after securing a specimen from a bent instrument, can be straightened and then removed from the patient's body through the cannula with the specimen intact.
Other objects, features and advantages will be apparent from the following detailed description of preferred embodiments taken in conjunction with the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a side elevational view of a surgical instrument of the type to which the present invention belongs.
FIG. 1B is a plan view of the surgical instrument shown in FIG. 1A.
FIG. 2A is a side elevational view of a surgical instrument of the present invention showing the bendable section and the effector end of the instrument.
FIG. 2B is a plan view of the surgical instrument shown in FIG. 2A with the bendable section in bent condition.
FIG. 3A is a plan view of one element of the bendable section of the surgical instrument.
FIG. 3B is a front elevational view of the element shown in FIG. 3A.
FIG. 3C is a bottom elevational view of the element shown in FIGS. 3A and 3B.
FIG. 3D is a side elevational view of the element shown in FIGS. 3A, 3B and 3C.
FIG. 4A is a side elevational view, partly in section, showing the bendable section of the surgical instrument in bent condition.
FIG. 4B is a side elevational view, partly in section, showing the bendable section of the surgical instrument in straight condition.
FIG. 5A is a plan view of one element of the bendable section of another embodiment of the surgical instrument.
FIG. 5B is a front elevational view of the element shown in FIG. 5A.
FIG. 5C is a bottom elevational view of the element shown in FIGS. 5A and 5B.
FIG. 5D is a side elevational view of the element shown in FIGS. 5A, 5B and 5C.
FIG. 6A is a bottom elevational view of a modified form of the element shown in FIGS. 3A, 3B, 3C and 3D.
FIG. 6B is a front elevational view of the element shown in FIG. 6A.
FIG. 6C is a plan view of the element shown in FIGS. 6A and 6B.
FIG. 7A is a partial elevational view partly in section of a modified instrument showing another embodiment of the invention.
FIG. 7B is a plan view of the instrument shown in FIG. 7A.
FIG. 7C is a side elevation of the instrument shown in FIGS. 7A and 7B.
FIG. 8 is a detailed sectional view of a detent mechanism used to hold the wires in place.
FIG. 9 is a detailed sectional view of a modified detent mechanism.
FIG. 10A is a side elevational view, partly in section, showing the bendable section in modified form used on a surgical instrument in bent condition.
FIG. 10B is a side elevational view, partly in section, showing the bendable section of the instrument of FIG. 10A in straight condition.
FIG. 11 is an isometric view of the instrument of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1A and 1B show a handle assembly 10 of an articulating, hand-held instrument 12 of a straight rigid design having a distal articulating assembly or end effector 14 of a grasping type, such as that used in surgery, electronic assembly and like applications. Such an instrument may be as described, for example, in U.S. Pat.No. 4,712,545, 4,043,343, and 1,754,806, but with a modified end and attachment base. It includes a fixed handle section 16, and an articulating handle portion 18. The grasping elements 20 of the handle portions are of closed-loop design.
The present invention is shown in FIGS. 2A and 2B which includes handle assembly 10, instrument 12, end effector 14, the end effector assembly 14 being steerable. The steering mechanism is made of standard end effectors attached to an actuating mechanism It also has a turnable device to rotate the end effector into a desired angular position after it has been introduced into a patient's body. It provides for rotating the end effector 14 about the longitudinal axis of the instrument. Such a mechanism is disclosed in copending application, Ser. No. 08/043,185, filed Apr. 6, 1993, and the disclosure thereof is incorporated herein by reference. Thus, the medical instrument 12 has a steerable distal end 14.
Once the distal end 14 passes through a cannula in the patient's body, the present invention allows the distal end 14 to move radially away from a straight linear line in a controlled steerable manner. It is controlled from the handle portion and allows the distal end to operate in three dimensions.
The handle 10, has a steering knob 22, attached to a middle section 24, which is connected to a bendable, steerable section 26, which is connected to a distal operating end 14 having jaws 27 or other similar devices. The bendable, steerable section is disposed close to the distal operating end. The bendable section 26 is made of a plurality of individual parts 28 (see FIGS. 4A and 4B) which are the same size and shape. When they are stacked together they allow a certain amount of angular movement between adjacent ones. The angular movement is permitted due to a cut-out portion 30 as will be described in more detail below.
There are three wires 32, 34 and 36, although element 36 could be a control rod. Wires 32 and 34 on the outside move and lock the individual parts 28, while the third wire, or rod, 36 runs through the center and controls the distal tips that do the cutting, grabbing, punching and the like. The center cable or rod 36 stays in the same relative position to the front tips 27 (see FIGS. 2A and 2B) and handle portion 10 during use of the bendable joint or section 26.
There is a central bore 40 (see FIGS. 3A, 3B and 3C) in each part 28 (see FIGS. 4A and 4B) through which cable or rod 36 fits to allow for a push and pull or rotatable actuator element to operate the effectors from the driver or handle area. The bore 40 is conical in shape. The joint will turn in only one plane because of the restriction of rotation of one part 28 to the next. This will allow the individual segments when assembled to move from a straight linear line to a radial curve in one direction only. The surgeon can rotate the entire distal end including the segment section and also use the device to move the distal end radially from a straight position.
Each stacked part or element 28 is constructed in a similar manner as shown in FIGS. 3A, 3B, 3C and 3D. The basic portion 42 is a disk shape and thus is round. Near the outer edge and 180 degrees apart are two straight bores 44 and 46 through which the control wires 32 and 34 are situated. Each element 28 has a rectangular extension 48 which projects from the disk shaped basic portion 42. The disk shaped basic portion 42 is hollowed out in the center on the side opposite the extension 48 to form a cavity 50. The cut-out 30 in the bottom surface of the disk shaped basic portion 42 is formed by a first end surface 52 and a second end surface 54 at the bottom surface of the element and which surfaces are parallel but offset from each other due to an inclined surface 56 connecting them. The extension 48 is slightly smaller than cavity 50 so that the extension of the adjacent element will extend into the cavity of the element. Furthermore, one side of the extension48, and this is the side where the first end surface 52 is located, is inclined at 58 as shown most clearly in FIG. 3B.
Thus, when a plurality of elements 28 are aligned with the parts in the same position, the extensions 48 project into the cavities 50 of adjacent elements. All the inclined surfaces 56 are aligned and so are the first end surfaces 52 and second end surfaces 54. When wire 34 (which is connected to an element connector 60 at connection point 62, which is the side on which the inclined surface 58 is disposed and on the side opposite where the cut-outs 30 are located) is moved in the direction of the arrow in FIG. 4B, the first end surfaces 52 of the elements are held together and the meeting parallel surfaces force them into aligned positions so that this section is straight as shown in FIG.4B. When wire 32, which is connected to element connector 60 at connection point 64, is moved in the direction of the arrow shown in FIG. 4A, wire 34 is moved in the direction of the arrow shown in FIG. 4A and the section is moved into the bent position shown in FIG. 4A.
The instrument, in the straight position as shown in FIG. 4B, is introduced into a patient's body through a cannula. When the surgeon needs to steer the distal end of the instrument in a particular direction out of this straight line position shown in FIG. 4B, he rotates the steerable knob 22 until the cutout side of the instrument faces the direction in which he or she wants to steer the distal end. The surgeon then moves wire 32 in the direction of the arrow shown in FIG. 4A and the instrument moves out of the straight line position as shown in this FIG. The control wire 36 is then used to move the end effector as desired.
Thus the bendable joint or section is made up of a number of individual pieces being the same size and shape which, when stacked together, allow a distinct amount of angular movement between any of them. The three wires or cables extend through the segments, the two outer ones moving and locking the individual pieces. The third runs through the center and controls the distal tips that are cutting, grabbing, punching, etc. The center cable stays in the same relative position to the front tips and handle portion during use of the bendable joint. Also, the central hole, through which the cable fits, allows for a push-pull or rotatable actuator element to operate the effectors from the driver. The joint will turn in only one plane because of the restriction of rotation of one piece to the next. The current configuration would allow the individual segments, when assembled, to move from a straight line to a radial curve in one direction only. With the feature of copending commonly assigned application Ser. No. 08/043,185 for a Surgical Instrument With Rotation, this allows the surgeon user to rotate the entire distal end including the segment section and also use the new invention to move the distal end radially from a straight position.
A modification of the element which allows the segment section to articulate in both directions from a center position by having two cut-out portions 180 degrees apart on each part is shown in FIGS. 5A, 5B, 5C and 5D.
There is a central bore 66 in each part 68 through which cable 36 fits to allow for a push and pull or rotatable actuator element to operate the effectors from the driver or handle area. The bore 66 is conical in shape. The joint will turn in only one plane because of the restriction of rotation of one part 68 to the next. This will allow the individual segments when assembled to move from a straight line to a radial curve in one direction only. The surgeon can rotate the entire distal end including the segment section and also use the device to move the distal end radially from a straight position.
Each stacked part or element 68 is constructed in a similar manner as shown in FIGS. 5A, 5B, 5C and 5D. The basic portion 70 is a disk shape and thus is round. Near the outer edge and 180 degrees apart are two straight bores 72 and 74 through which the control wires 32 and 34 are situated. Each element 68 has a rectangular extension 76 which projects from the disk shaped basic portion 70. The disk shaped basic portion 70 is hollowed out in the center on the side opposite the extension 76 to form a cavity 78. The cut-outs 80 in the bottom surface of the disk shaped basic portion 70 is formed by a first end surface 82 and a second end surface 84 at the bottom surface of the element and which surfaces are aligned with each other. There is a projection 86 formed by two inclined surfaces 88 connected together. The extension 76 is slightly smaller than cavity 78 so that the extension of the adjacent element will extend into the cavity of the element. Furthermore, two sides of the extension, inclined at 90 are shown most clearly in FIG. 5B.
Thus, when a plurality of elements 68 are aligned with the parts in the same position, the extensions project into the cavities of adjacent elements. When wire 34, which is connected to an element connector 60 at 62, which is the side on which one of the inclined surfaces 90 are disposed is moved in the direction of the arrow in FIG. 4B, the first end surfaces 82 of the elements are held together and depending upon how far the wire is moved, the elements will be parallel, in which condition the bendable section is straight, or will be moved so that the surfaces 82 are moved closer together, in which condition the bendable section will flex in the direction of the aligned end surfaces 82. When wire 32, which is connected to an element connector 60 at 64, which is the side on which the other of the inclined surfaces 90 is disposed is moved opposite the direction of the arrow shown in FIG. 4B, the second end surfaces 84 of the elements are held together and, depending upon how far the wire is moved, the elements will be parallel, in which condition the bendable section is straight, or will be moved so that the surfaces 84 are moved closer together, in which condition the bendable section will bend in the direction of the aligned end surfaces 84, which is 180 degrees from the direction when the wire 34 is moved.
The instrument, in the straight position as shown in FIG. 4B, is introduced into a patient's body through a cannula. When the surgeon needs to steer the distal end of the instrument in a particular direction out of this straight line position shown in FIG. 4B, he rotates the steerable knob 22 until one of the cutout sides of the instrument faces the direction in which he wants to steer the distal end. He then moves wire 32 or 34 in the direction of the arrow and the instrument moves out of the straight line position into one of two directions 180 degrees apart. The control wire 36 is then used to move the end effector as desired.
Thus, the bendable joint or section is made up of a number of individual pieces being the same size and shape which, when stacked together, allow a distinct amount of angular movement between any of them. The three wires or cables extend through the segments, the two outer ones moving and locking the individual pieces. The third runs through the center and controls the distal tips that are cutting, grabbing, punching, etc. The center cable stays in the same relative position to the front tips and handle portion during use of the bendable joint. Also, the central hole, through which the cable fits, allows for a push-pull or rotatable actuator element to operate the effectors from the driver.
The joint will turn in only two planes because of the restriction of rotation of one piece to the next. The current configuration would allow the individual segments, when assembled, to move from a straight linear line to a radial curve in two directions only.
A modification of the element shown in FIGS. 3A, 3B, 3C and 3D is shown in FIGS. 6A, 6B and 6C in which only the differences are labeled with lead lines and reference numerals. The bore 92 through the center of the element in this embodiment tapers in the opposite direction than bore 40 in the first embodiment. Also, the bore has a chamfer at 94. There are 4 counter bores 96, 97, 98 and 99 at the corners of the cavity 95.
FIGS. 7A, 7B, 7C and 8 show a modified instrument showing another embodiment of the invention. There is a handle 10 as well as a steering knob device 22 (see FIGS. 2A and 2B). However, between them is a control and restraining mechanism 100 for the control wires 32 and 34 (see FIGS. 4A and 4B) which are used to bend the bendable section 26 (see FIGS. 2 A, 2B, 4A and 4B) into extreme positions as well as intermediate positions. The wire 32 can be pulled to any number of intermediate positions to provide as much or little bend as desired. To straighten the bendable section 26, one pulls the wire 34 to an extreme position and the surgeon knows without looking that the section is straight and can be removed from the patient's body through the cannula. The angular position of the end effector is controlled by the steering knob device which includes a cylinder 102 which can be rotated to move the end effector 27 (see FIGS. 2A and 2B) into the desired position. This cylinder 102 is located close to the handle 10 so that it and the control and restraining mechanism 100, as well as the end effector 27 can be operated by the surgeon with one hand.
The control and restraining mechanism 100, includes a cylindrical housing 104 having two sets of grooves 106 and 108 in the interior of the cylindrical walls at the two extreme ends of the movement of the wires. Within the housing 104 is a rotor 110 which rotates within the housing 104. The rotor 110 includes wire holding elements 112 to hold the wires in position and thus the bendable section in position. Wire 32 is fixed in the rotor at rotor connection 114 while wire 34 is fixed in the rotor at rotor connection 116 spaced 180 degrees therefrom. There is a cylindrical bore 118 in rotor 110 in which are two biased cylinders 120 having a spring 122 between them to bias them outwardly toward the walls of the housing 104. The outer surfaces of cylinders 120 are smooth and slightly curved so they act like detents to hold the rotor into position when the cylinders are in the detents in the two extreme positions. In one of these positions the cylinders 120 are in the grooves 106 and in the other extreme position the cylinders are in the grooves 108. Thus, a 90 degree movement is all that is needed to move the bendable section between the straight and the most extreme bent position.
The control and restraining mechanism 100 which includes the cylinder 102 of the steering knob device 22 are both mounted for rotation together so that when the cylinder has its angular position changed, such as when the surgeon is positioning the end effector angularly, the wire control device rotates therewith.
Thus, when it is desired to change the position of the bendable section from straight to bent or vice versa, the lever 124 is moved 90 degrees which rotates the rotor 110 to move the control wires 32 and 34.
FIG. 9 is a detailed sectional view of a modified detent mechanism in which there are many additional grooves 126, in positions between the extreme position grooves 106 and 108 so that detents hold the position of the wire control even between the two extreme positions.
The control wires can be held in place to maintain the bendable section in a desired position by having the wires held by a resistance, possibly with a control knob or a brake mechanism.
FIGS. 10A and 10B show the bendable section in modified form used on a surgical instrument in bent condition and in straight condition. In this embodiment there is a sheath 128 composed of resilient material which surrounds at least the bendable section to protect it and prevent tissue from the patient's body from becoming entrapped in the openings between the elements.
There are two different embodiments of the actuating mechanism. In one it articulates with a push, and in the second it is reverse and the tip articulates with a pull which has the advantage of increasing the rigidity of the assembly.
The end effector does not have to be controlled with a push-pull motion, but can be controlled by a rotational motion from the handle.
It will now be apparent to those skilled in the art that other embodiments, improvements, details, and uses can be made consistent with the letter and spirit of the foregoing disclosure and within the scope of this patent, which is limited only by the following claims, construed in accordance with the patent law, including the doctrine of equivalents.
|
A medical instrument with a steerable distal end, having a handle for actuating the instrument, a distal operating section for performing a medical procedure, a middle section connecting the handle with the operating section, at least a portion of the middle section being bendable, and steerable means within the bendable portion for permitting the operating section to be controlled in direction at an angle with respect to the axis of the middle section. There are means for rotating the distal operating section into any desired angular position with respect to the longitudinal axis of the middle section. A control member control the direction of movement of the bendable section in three dimensions whereby the distal end may be positioned in any place on or off of the longitudinal axis of the middle section. A protective sheath may be disposed over the bendable section.
| 0
|
DESCRIPTION
1. Technical Field
The present invention relates to a method for controlling a liquid and gaseous hydrocarbons production well of the gushing type which feeds a downstream treatment unit.
2. State of the Prior Art
A known process for controlling the production flow rate of an oil well of the gushing type which comprises a hydrocarbons production column connecting the bottom of the well to a wellhead, connected by a pipe through a variable-aperture outlet choke to a downstream unit for treating the produced hydrocarbons, consists in positioning the outlet choke to set value so as to obtain a given produced-hydrocarbons flow rate.
This process does not allow effective control over the production of the hydrocarbons when plugs of gas form when the well starts production, as a result of the opening of the outlet choke, or when alternating plugs of gaseous and of liquid hydrocarbons occur, which plugs may be formed particularly in wells which have long drains with shallow, negative and varying gradients.
These plugs disrupt the production of hydrocarbons and this is manifested in an irregular supply to the downstream treatment units, such as liquid/gas separation units, or units for recompressing and processing the gas.
This irregular supply to the downstream treatment units has the following consequences:
it reduces the amount of gas that can be recompressed to be reinjected into the well or for sale,
it increases the wear on the equipment of these units, and
it increases the risks of tripping, which is manifested in a reduction in production.
Another consequence of these disturbances is an accentuation of the wear on the hole layer connection, particularly in wells sunk into unconsolidated reservoirs, and this leads to the ingress of sand which requires the installation of expensive sand-control equipment which may reduce the production capacity of the well or lead to frequent and expensive restoration of damaged wells.
Something else which this method is unable to provide is control over the initiation of a preferred flow of gas or water towards the bottom of the well from a zone of the reservoir which has been invaded by hydrocarbons in the gaseous form or by water.
Nor is it able to effectively compensate for the disruptions which result from the random behaviour of the reservoir, or for failure of the production column equipment.
The present invention is intended precisely to overcome these drawbacks, and to this end it provides a method for controlling a liquid and gaseous hydrocarbons production well of the gushing type, the well comprising at least one production column extended at its upper part by an outlet pipe for the produced hydrocarbons and fitted with variable-aperture means of controlling the hydrocarbons flow rate, the method being characterized in that it comprises a start-up phase which consists in performing the following sequence of steps:
a step of initiating hydrocarbons production which consists:
in gradually opening the control means to a predetermined value so as to achieve a predetermined minimum produced-hydrocarbons flow rate,
in comparing the hydrocarbons flow rate with a predetermined threshold and if the said flow rate exceeds the said threshold, in suspending the opening of the control means for the duration that the threshold is exceeded,
a step of ramping up to production speed which consists in performing the following operations:
comparing the produced-hydrocarbons flow rate with a predetermined threshold T 1 and if the said flow rate exceeds the said threshold continuously for a predetermined length of time D 1 , in increasing the aperture of the control means to a predetermined value, otherwise repeating the comparison,
waiting for a predetermined length of time to allow the minimum hydrocarbons flow rate to become established,
comparing the produced-hydrocarbons flow rate with a threshold T 2 higher than T 1 and comparing the pressure upstream of the control means with a predetermined threshold P 1 and if the said flow rate and the said pressure simultaneously exceed the said thresholds continuously for the length of time D 1 , in finishing the start-up phase, otherwise repeating the comparison.
According to another feature, the method of the invention additionally consists in periodically performing the following operations:
calculating the derivative with respect to time of the pressure upstream of the means for controlling the produced-hydrocarbons flow rate,
comparing this derivative with a predetermined negative threshold and with a predetermined positive threshold and if the derivative of the pressure is below the negative threshold or if the said derivative is above the positive threshold, in suspending the opening of the means for controlling the produced-hydrocarbons flow rate.
According to another feature of the invention, the start-up phase additionally consists in performing the following operations:
calculating a well demand criterion,
comparing this criterion with a predetermined threshold,
if the criterion exceeds this threshold, suspending the opening of the means for controlling the produced-hydrocarbons flow rate.
According to another feature of the invention, the start-up phase is followed by a production phase which consists in performing the following operations:
defining a production indicator,
comparing the production indicator with two predetermined thresholds S 1 , S 2 , S 2 being higher than S 1 , and:
a) if the production indicator is below S 1 , and if the aperture of the means for controlling the produced-hydrocarbons flow rate is below a predetermined threshold, in increasing the aperture of the said control means by a predetermined amount,
b) if the production indicator is above S 2 , and if the aperture of the means for controlling the produced-hydrocarbons flow rate is above a predetermined threshold, in reducing the aperture of the said control means by a predetermined amount,
c) in repeating the previous comparison,
comparing the produced-hydrocarbons flow rate with a predetermined threshold and if the said flow rate is below the said threshold, in closing the produced-hydrocarbons control means for a predetermined length of time and in resuming the start-up phase.
According to another feature of the invention, the start-up phase is followed by a production phase which consists in performing the following operations:
defining two production indicators Qa and Qb,
comparing these two indicators Qa and Qb with, respectively, two pairs of predetermined thresholds Sa 1 , Sa 2 and Sb 1 , Sb 2 , Sa 2 being higher than Sa 1 and Sb 2 being higher than Sb 1 :
a) if Qa is below Sa 1 and if Qb is below Sb 1 and if the aperture of the means for controlling the produced-hydrocarbons flow rate is below a predetermined threshold, in increasing the aperture of the said control means by a predetermined amount
b) if Qa is above Sa 2 and if Qb is above Sb 2 and if the aperture of the means for controlling the produced-hydrocarbons flow rate is above a predetermined threshold, in reducing the aperture of the said control means by a predetermined amount,
c) in repeating the previous comparison,
comparing Q 1 and Q 2 with, respectively, two predetermined thresholds S 1 and S 2 and if Q 1 is below S 1 or if Q 2 is above S 2 , in closing the means for controlling the produced-hydrocarbons flow rate for a predetermined length of time and in resuming the start-up phase.
According to another feature of the invention, with the produced liquid hydrocarbons containing water, at least one production indicator is the flow rate of the said hydrocarbons.
According to another feature of the invention, with the produced liquid hydrocarbons containing water, at least one production indicator is the flow rate of liquid hydrocarbons without water.
According to another feature of the invention, with the produced liquid hydrocarbons containing water, at least one production indicator is the water flow rate.
According to another feature of the invention, at least one production indicator is the flow rate of produced gaseous hydrocarbons.
According to another feature of the invention, the production phase additionally consists in performing the following operations:
calculating a well demand criterion
comparing this criterion with a predetermined threshold,
if the criterion exceeds this threshold, in reducing the aperture of the means for controlling the produced-hydrocarbons flow rate by a predetermined amount.
According to another feature of the invention, the demand criterion is calculated from a physical parameter measured on the well.
According to another feature of the invention, the means for controlling the produced-hydrocarbons flow rate comprise an outlet choke arranged on the outlet pipe.
According to another feature of the invention, with the production column extended at its lower part by at least one hydrocarbons collection drain, the means for controlling the produced-hydrocarbons flow rate comprise at least one automatic bottom valve arranged on at least one drain.
According to another feature of the invention, the means for controlling the produced-hydrocarbons flow rate additionally comprise an outlet choke arranged on the outlet pipe.
According to another feature of the invention, the produced-hydrocarbons flow rate is measured by means of a flow meter mounted on the outlet pipe.
According to another feature of the invention, the produced-hydrocarbons flow rate is estimated from a measurement of the produced-hydrocarbons temperature in the outlet pipe.
According to another feature of the invention, the produced-hydrocarbons flow rate is estimated from the pressure difference across the means for controlling the produced-hydrocarbons flow rate and from the aperture of the said means.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood from reading the following description which is given by way of example with reference to the appended drawings, in which:
FIG. 1 diagrammatically depicts a hydrocarbons production well of the gushing type, fed by a single reservoir,
FIG. 2 diagrammatically depicts a hydrocarbons production well of the gushing type comprising two production drains fed by two reservoirs.
DETAILED DESCRIPTION OF THE INVENTION
In general, the method of the invention is used to control a hydrocarbons production well which supplies downstream treatment units.
FIG. 1 depicts a well 1 for producing hydrocarbons in the form of a mixture of liquid and gas of the gushing type, which comprises:
a production column 2 ,
a casing 3 surrounding the column 2 ,
a downstream unit 5 for processing the hydrocarbons produced,
an outlet pipe 4 for the produced hydrocarbons, connecting the upper part of the column 2 to the downstream treatment unit 5 through a controllable variable-aperture outlet choke 9 forming means for controlling the produced-hydrocarbons flow rate,
a sensor 6 for measuring pressure downstream of the choke 9 , which delivers an electronic signal which represents this pressure,
a sensor 7 for measuring the temperature upstream of the choke 9 , which delivers an electronic signal which represents this temperature,
a sensor 8 for measuring the pressure upstream of the choke 9 , which delivers an electronic signal which represents pressure,
a programmable controller 10 with inputs 13 , 14 and 15 which respectively receive the electronic signals delivered by the sensors 6 , 7 and 8 , and an output 12 which delivers a signal controlling the position of the output choke 9 ,
means 11 for dialogue between operator and controller 10 .
The controller 10 additionally comprises, and this is not depicted in FIG. 1, a memory previously loaded with a control program and with the data needed for controlling the well, particularly all the predetermined values of the adjustment variables. This data is entered beforehand by an operator using the operator/controller dialogue means 11 and can be updated during production using the same means.
Some of this data may be entered by a control-assistance computer, not depicted in FIG. 1 .
Before the well 1 enters service, the outlet choke 9 is closed.
The method of the invention employed for controlling the well 1 comprises a start-up phase consisting of two steps.
A first step of initiating the production of hydrocarbons, during which step the controller 10 gradually opens the choke 9 to a predetermined value which is calculated to ensure that the produced hydrocarbons reach a predetermined minimum flow rate, for example 25% of the flow rate for which the well was designed, and compares with a predetermined threshold, for example 150% of the minimum flow rate, the hydrocarbons flow rate estimated from a temperature measurement supplied by the sensor 7 , using the following formula:
Q=Qo+λ{square root over (T−To)}
in which:
Q represents the estimated produced-hydrocarbons flow rate,
Qo, To and λ are characteristic constants of the well,
T is the temperature of the hydrocarbons in the pipe 4 supplied by the sensor 7
if the estimated flow rate exceeds this threshold, then the controller 10 suspends the opening of the choke 9 by maintaining the control signal at its last value on the output 12 until the threshold is no longer exceeded.
Once the step of initiating the production of hydrocarbons is thus finished, the start-up phase continues with the performing of a step of ramping up to production speed, during which step the controller 10 performs the following operations.
It compares the produced-hydrocarbons flow rate, estimated as previously from the temperature measurement supplied by the sensor 7 , with a predetermined threshold T 1 which represents the minimum flow rate, namely, for example, 25% of the flow rate for which the well was designed.
If the estimated produced-hydrocarbons flow rate continuously exceeds the threshold T 1 for a length of time D 1 which is predetermined as a function of the well characteristics, for example 20 min, the controller 10 delivers on its output 12 a signal to open the choke 9 to a predetermined value, for example 30% of its maximum aperture.
Otherwise, the controller 10 repeats the previous comparison.
When the produced-hydrocarbons flow rate is practically stabilized, that is to say after waiting for a predetermined length of time that corresponds to the time taken to sweep the production column 2 and after waiting for the start of flow in the drainage area around the well, for example 60 min, the controller 10 :
compares the produced-hydrocarbons flow rate estimated from the temperature measurement upstream of the choke 9 supplied by the sensor 7 , with a threshold T 2 higher than T 1 , for example 50% of the production flow rate for which the well was designed,
compares the pressure upstream of the choke 9 , measured by the sensor 8 , with a predetermined pressure threshold P 1 .
If, simultaneously, the estimated produced-hydrocarbons flow rate exceeds the threshold T 2 and the pressure upstream of the choke 9 exceeds the threshold P 1 for a predetermined length of time, for example 20 min, the controller 10 performs the operations of the production phase.
If this double condition is not satisfied, the controller 10 repeats the comparison of the produced-hydrocarbons flow rate with the thresholds T 1 and T 2 .
Once the start-up phase has finished, the method of the invention comprises a production phase during which the controller 10 performs the following operations:
it calculates two production indicators Qa and Qb
Qa is the produced-hydrocarbons flow rate estimated from the temperature T upstream of the choke 9 , using the above formula
Qb is the produced-hydrocarbons flow rate estimated from the pressure difference across the choke 9 , using the following formula:
Q=k×Pupstream×[{square root over ((Pupstream-Pdownstream)})/{square root over ((Pupstream))}]×S
if Pdownstream>0.5×Pupstream
and
Q=k×Pupstream×0.707×S if Pdownstream<0.5×Pupstream
in which
Q represents the estimated produced-hydrocarbons flow rate,
k is a constant,
S is the passage cross-sectional area of the choke 9 ,
Pupstream and Pdownstream are, respectively, the pressures upstream and downstream of the choke 9 , measured respectively by the sensors 8 and 6
compares the indicators Qa and Qb respectively with two thresholds ST 1 , ST 2 and SP 1 , SP 2 .
ST 1 , ST 2 , SP 1 and SP 2 are predetermined as a function of the flow rate for which the well was designed, for example:
ST 1 =75% of the hydrocarbons flow rate for which the well was designed
ST 2 =90% of the hydrocarbons flow rate for which the well was designed
SP 1 =80% of the hydrocarbons flow rate for which the well was designed
SP 2 =110% of the hydrocarbons flow rate for which the well was designed.
If Qa is below ST 1 and Qb is below SP 1 , and if the aperture of the choke 9 is below a threshold which is predetermined as a function of the well characteristics, for example 60% of the maximum aperture, the controller 10 increases the aperture of the choke 9 by a predetermined amount, for example 3% of the maximum aperture.
If Qa is above ST 2 and if Qb is above SP 2 and if the aperture of the choke 9 is above a threshold which is predetermined as a function of the well characteristics, for example 30% of the maximum aperture, the controller 10 reduces the aperture of the choke 9 by a predetermined amount, for example 3% of the maximum aperture.
Otherwise, the controller 10 repeats the previous operations.
In parallel, the controller 10 compares Q 1 and Q 2 respectively with two predetermined thresholds S 1 and S 2 , S 1 being equal to 25% of the hydrocarbons flow rate for which the well was designed and S 2 being equal to 40% of the same flow rate, and if Q 1 is below S 1 or if Q 2 is above S 2 , the controller 10 resumes the startup phase from its beginning.
During the start-up and production phases, the controller 10 monitors the rate at which the pressure in the pipe 4 changes upstream of the choke 9 , comparing the derivative of this pressure with respect to time with a positive threshold, for example 1 bar per minute, and with a negative threshold, for example −1 bar per 5 minutes, and if the derivative of pressure does not lie between these two threshold values, the controller 10 suspends the opening of the choke 9 .
During these two phases, it also calculates a well demand criterion on the basis of a physical parameter measured on the well, for example the pressure at the bottom of the well measured by means of a sensor not depicted in FIG. 1, applying the following formula:
C=a×(Pstat−P)
in which:
C represents the demand criterion,
a is a constant
Pstat represents the static pressure at the bottom of the well, that is to say the well bottom pressure in the absence of any hydrocarbons flow rate,
P represents the well bottom pressure during production.
The controller 10 compares C with a threshold which is predetermined as a function of the mechanical strength characteristics of the reservoir and if this threshold is exceeded it delivers a signal to close the outlet choke 9 , to for example 5% of its maximum aperture.
Other physical parameters may be used as well demand criterion, such as the sand flow rate in production, when the hydrocarbons contain sand, the pressure in the annular space defined by the production column 2 and the casing 3 which surrounds it, a temperature at some point in the well or a mechanical parameter of an item of well equipment.
By virtue of the alteration of the position of the outlet choke in accordance with the method of the invention, the first plug of gas and the first plug of liquid which occur during the start-up phase are greatly damped and production is increased gradually in a stable manner and then constantly maintained at a target value.
By virtue of the monitoring of the rate of change of pressure in the outlet pipe and of the value of a demand criterion, the risk of well damage is reduced.
The method of the invention implemented for controlling the hydrocarbons production well described above is not restricted to the control of this type of well, it also applies, through adaptations that are within the competence of the person skilled in the art of the invention, to the control of other types of gushing well such as:
of the “multidrain” type, in which the production column is fed by several drains which pass through one or more reservoirs,
of the type depicted in FIG. 2 which has two reservoir zones 21 and 22 isolated by a seal 23 , and an automatic valve 20 which can be controlled from the controller 10 , which valve makes it possible to alter the contribution made by the reservoir 21 to the production of hydrocarbons.
|
A method for controlling a gushing hydrocarbon production well is disclosed which utilizes a variable aperture outlet choke and a control system to dampen and minimize the effect of liquid and gas plugs flowing through the system.
| 4
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is in the field of construction, pertaining more specifically to the art of framing in construction and methods and apparatus for securing and locking structural members into position, applicable in many areas, such as construction for sub flooring, ceiling, roof, and other framings requiring structural members, and for structures in furniture, containers, models, and temporary shelters, among many other uses.
[0003] 2. Discussion of the State of the Art
[0004] In the field of framing for construction joisting is regularly employed to form a load-bearing floor, roofing, or ceiling framework comprising of multiple structural members laid parallel to one another and fastened to common end plates or beams. A typical structural member defines the elongate member laid with other like members to form a sub-floor, roof, or a ceiling truss. In constructions of differing materials the structural members are laid somewhat uniformly in the arrangements or structures according to certain standards set for those types of constructions. A problem with standard joisting is that it is limited to simple or continuous spans with bearing-type connections and is particularly weak with respect to resisting force from certain directions variant from typical load-bearing (vertical) forces or dead weight.
[0005] Depending on construction materials used in a particular project, there are various standard methods for securing structural members to each other and to end plates. Nails, screws, metal bracing, and other components may be used depending on specifications for the construction project. A problem with typical joisting and joisting with prefabricated truss works is that other than vertical load-bearing, there is no inherent structural integrity for resisting certain directional forces that can occur such as wind shear, earthquake, and other forces.
[0006] Therefore, what is clearly needed is a structural member lock and positioning system that distributes load resistance to vertical members across the construction and adds structural strength to resist forces other than vertical load forces.
SUMMARY OF THE INVENTION
[0007] In an embodiment of the present invention a structural assembly is provided comprising a first set of first elongate structural members alternately spaced apart from a second set of second elongate structural members by locking blocks, the first set defining a first plane and the second set defining a second plane forming an intersection at an angle with the first plane, the structural members and locking blocks defining an assembly of adjoined blocks and structural members at the intersection, and a compressive mechanism spanning the assembly of adjoined blocks and structural members at the intersection. Compressing the adjoined blocks and structural members by the spanning compression mechanism locks the blocks and structural members together in a manner to resist applied forces.
[0008] In one embodiment the compressive mechanism comprises a rod, wire or cable passing through aligned openings in the adjoining blocks and structural members at the intersection, and one or more elements applying tension to the rod, wire or cable. Also in one embodiment the structural members and the blocks have complementary shape such that adjoining blocks and structural members engage at a specific angle defined by the engagement shapes of the blocks.
[0009] In some embodiments the structural members have an I-beam shape with a central planar member and wider rails at each end, the locking blocks have channels to engage the wider rails, with sets of channels on opposite sides to engage adjacent structural members, with the sets of channels oriented at an angle to one another, defining the angle of the planes at the intersection. Also in some embodiments there may be a third set of structural members defining a third plane parallel to the first plane and a fourth set of structural members defining a fourth plane parallel to the second plane, the first and second planes intersecting at a first intersection at ninety degrees, the second and third planes intersecting at a second intersection at ninety degrees, the third plane and the fourth plane intersecting at a third intersection at ninety degrees, and the fourth plane and the first plane intersecting at a fourth intersection at ninety degrees, the four planes defining a rectangular box.
[0010] In some embodiments there panels fastened to the separate sets of structural members, providing a top, a floor, and two sides to the structural assembly.
[0011] In another aspect of the invention a method for making a rigid structural assembly is provided, comprising the steps of (a) spacing apart a first and a second set of elongate structural members alternately with locking blocks such that the first set defines a first plane and the second set defines a second plane in an intersection at an angle with the first plane, the structural members and locking blocks defining an assembly of adjoined blocks and structural members at the intersection; and (b) compressing the adjoined structural members and inter-spaced locking blocks at the intersection with a spanning compression mechanism.
[0012] In one embodiment of the method the compressive mechanism comprises a rod, wire or cable passing through aligned openings in the adjoining blocks and structural members at the intersection, and one or more elements applying tension to the rod, wire or cable. In another embodiment the structural members and the blocks have complementary shape such that adjoining blocks and structural members engage at a specific angle defined by the engagement shapes of the blocks.
[0013] Also in some embodiments of the method the structural members may have an I-beam shape with a central planar member and wider rails at each end, the locking blocks have channels to engage the wider rails, with sets of channels on opposite sides to engage adjacent structural members, with the sets of channels oriented at an angle to one another, defining the angle of the planes at the intersection.
[0014] In some embodiments there may be a third set of structural members defining a third plane parallel to the first plane and a fourth set of structural members defining a fourth plane parallel to the second plane, the first and second planes intersecting at a first intersection at ninety degrees, the second and third planes intersecting at a second intersection at ninety degrees, the third plane and the fourth plane intersecting at a third intersection at ninety degrees, and the fourth plane and the first plane intersecting at a fourth intersection at ninety degrees, the four planes defining a rectangular box. Also in some cases there are panels fastened to the separate sets of structural members, providing a top, a floor, and two sides to the structural assembly.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0015] FIG. 1 is perspective view of a frame assembly according to an embodiment of the invention.
[0016] FIG. 2 is a perspective view of the assembly of FIG. 1 flipped around to illustrate the inside construction of the assembly.
[0017] FIG. 3 is a perspective view of the structural members of FIGS. 1 and 2 .
[0018] FIG. 4 is a perspective view of the structural member lock of FIG. 1 according to an embodiment of the invention.
[0019] FIG. 5 is a plan view of a structural member assembly according to an embodiment of the invention.
[0020] FIG. 6 is a perspective view of a structural member assembly locked at an angle other than 90 degrees.
[0021] FIG. 7 is a plan view of an angled structural member assembly according to an embodiment of the invention.
[0022] FIG. 8A is a perspective view of a torsion locking block according to another embodiment of the present invention.
[0023] FIG. 8B is a perspective view of a torsion locking block according to another embodiment of the present invention.
[0024] FIG. 9 is an illustration of a basic box structure according to an embodiment of the invention.
DETAILED DESCRIPTION
[0025] FIG. 1 is perspective view of a frame assembly 100 according to an embodiment of the invention. Frame assembly 100 is a framing configuration in construction that provides a construction framing for floors, walls, and ceilings of a structure or building. Assembly 100 consists of multiple structural members 101 and 102 positioned and locked into place by multiple torsion locking blocks 103 placed between each of vertical structural members 101 and horizontal structural members 102 . In this example, structural members 101 and 102 are identical to one another in physical description and may be used as either vertical or horizontal members.
[0026] Structural members 101 and 102 may be made of wood, steel, aluminum, or some other durable material suitable for building construction. Torsion locking blocks 103 may be made of wood, steel, aluminum, or some other durable material suitable for building construction. Structural members 101 and 102 have physical features that interface and engage with physical features on the joist-interfacing sides of torsion locking devices 103 in this configuration.
[0027] In this example there are 4 vertical structural members 101 and 4 horizontal structural members 102 assembled with 7 torsion locking blocks 103 . This framing example may represent, for example, a junction of a sub floor and vertical wall framing of a building under construction. It will be appreciated by one with skill in the art of construction that the entire building frame is not represented in this example. In this case the structural members are secured at a right angle ( 90 degrees), common for floor-to-wall interfaces. The structural members are secured to the locking blocks at their ends in this example. In other construction configurations the angle may differ from 90 degrees and the structural members may intersect with torsion locking blocks at any intersection point placed along the length of those members.
[0028] A compression system 105 is provided to compress the collective components of the assembly together in the geometric configuration shown. Compression system 105 comprises a solid and durable elongate bar or rod 107 that passes through openings located in structural members 101 and 102 and in torsion locking blocks 103 . System 105 may include compression washers and tensioning nuts applied to the ends of the assembly to secure and compress the assembly together. The elongate rod 107 used may be manufactured of steel or another solid and durable material capable of serving as a compression medium without failing under tensioning applied at the ends of the assembly.
[0029] In alternative embodiments cable or wire may be used rather than a rod or bar, and various tensioning mechanisms may be used to compress the structural members and the locking blocks together.
[0030] Assembly 100 is superior in strength to other construction geometries using structural members because the torsion locking blocks 103 together with the compression system 105 applied to secure the assembly provide transfer of shear, torsion, and moment forces laterally between adjacent structural members 101 and 102 in a direction substantially perpendicular to the direction of the structural members in the assembly.
[0031] Assembly 100 includes multiple exterior and interior panels 104 that help to secure the structural members together with other structural members in the assembly. Panels 104 are attached in this example to the assembly at the outside and inside edges of the structural members. Panels 104 may be manufactured of plywood, metal sheeting, fiberglass sheeting, or other relatively stiff material. Panels 104 help to ensure transfer of shear and moment forces across the assembly, but are not essential in the broad aspects of this invention. Exterior panels 104 come together at the rear edge of the assembly and are fastened to the assembly with the aid of a blocking element 106 (interior blocking element visible).
[0032] Blocking elements 106 are positioned both on the exterior and interior sides of the assembly and are connected between the structural members 101 and 102 , and torsion locking blocks 103 . Blocking elements 106 have fasteners that tie the components together when panels 104 are added to the assembly. Blocking elements 106 provide a continuous load path between the other elements of the assembly and further allow adjacent panels 104 to be connected or secured across their lateral intersection. Blocking elements 106 may be manufactured from wood, steel, aluminum, or some other solid and durable material capable of load transfer.
[0033] FIG. 2 is a perspective view of the assembly of FIG. 1 rotated to illustrate the inside construction of the assembly in this example. In this view blocking elements 106 are visible in position between horizontal structural members 102 and vertical structural members 101 . Fasteners holding blocking elements in position and to panels 104 are not visible in this example but are assumed present. The construction and type of fasteners used will depend on the material selection of the components in the assembly. The exact method of fastening is not relevant to the invention.
[0034] FIG. 3 is a perspective view of one each of structural members 101 and 102 of FIGS. 1 and 2 , shown isolated. Structural member 101 and structural member 102 are identical to each other in physical description in this embodiment, but may differ somewhat in other embodiments. In this example the shared physical features between structural members 101 and structural members 102 have the same element numbers and description. Each structural member 101 and 102 consists of substantially parallel rails 302 formed along longitudinal edges of the structural members. A thinner middle body 301 is disposed between rails 302 forming a complete structural member much in the manner of an I-beam. In a preferred embodiment, structural members 101 and 102 are contiguous parts formed of the same material. In some embodiments rails 302 may be separate components joined to middle body 301 to form a structural member that may function as a part formed of one material.
[0035] In this example, rails 302 are rectangular in profile. The rectangular portion of each rail 302 on one side of body 301 is of a dimension that fits into channels provided on interfacing sides of the torsion locking blocks. The I-beam construction profile of structural members 101 and 102 provides sufficient transfer of load forces and is particularly suited for strength. Structural members 101 and 102 each have openings 303 in alignment with one another in appropriate configuration for assembly with the interspaced locking blocks. Openings 303 are sized to accept the tensioning bar or rod 107 .
[0036] Structural members 101 and 102 have each have openings 303 at locations along each structural member where a torsion structural member lock may be placed, not necessarily just at the ends of the members. Further, structural members 101 and 102 may be of any required length for construction. The structural members may be assembled using a torsion structural locking block at any desired linear angle including 180 degrees. In one embodiment the angle of construction of the structural members is set by the construction of the torsion structural member locks. For example, a 90-degree angle would require a 90-degree torsion structural member lock.
[0037] FIG. 4 is a perspective view of a torsion locking block 103 of FIG. 1 according to an embodiment of the invention. Torsion locking block 103 may be manufactured of steel, wood, fiberglass, or other construction materials. Locking block 103 in this example is quadrilateral in shape having 4 sides, a top surface and a bottom surface. Sides 402 and 404 are the sides that interface with structural members. Sides 406 and 405 do not interface with structural members. Opposing sides of structural member block 103 are substantially parallel to each other as are the top and bottom surfaces.
[0038] In one embodiment torsion locking block 103 is of a solid construction. In another embodiment, locking block 103 may be manufactured of separate components that fit together to function as one piece. One or more openings 407 are provided at or around the approximate center of locking block 103 extending from side 402 through side 404 . Opening 407 is a through-bore and has a diameter sufficiently large for accepting the tensioning rod 107 , or whatever tensioning element is to be used.
[0039] Torsion locking block 103 has a pair of channels 401 along opposing edges of side 402 . Channels 401 are identical to one another in depth and function to accept the rails provided on the structural members 101 and 102 . Channels 401 are substantially symmetrical and extend the length of side 402 in a horizontal direction for supporting one of horizontal structural members 102 described further above. The spacing between the opposing shelf walls is just small enough to accept the spacing between the inner opposing walls of the rails of a structural member. Channels 401 have a depth measured from surface 402 that is just large enough to enable the structural member body in between the rails to interface flush against surface 402 . The fit is tight enough so that there is very little or no movement in the angle of the assembly.
[0040] On surface 404 there is a like pair of channels 403 provided in orientation rotated approximately 90 degrees from channels 403 to accept vertical structural members 101 described earlier. In this embodiment, torsion locking block 103 is a 90-degree block, meaning that adjacent structural members abutting the locking block are disposed linearly at a 90-degree angle such as where a floor meets a vertical wall. However, other torsion locking blocks may be provided of varying angles between 0 and 180 degrees.
[0041] FIG. 5 is a plan view of a structural member assembly 500 according to an embodiment of the invention. Structural member assembly 500 includes 2 horizontal structural members 102 spaced evenly apart in assembly from a vertical structural member 101 by 2 torsion locking blocks 103 . In this example, the assembly is secured and compressed by compression system 105 , which includes in this instance a rod 502 passing through the assembly and held in place by tensioning nuts 501 at either end of the assembly. Applying tension to the assembly provides the compression needed to ensure transfer of lateral shear and moment forces through the assembly, equally distributing the load.
[0042] FIG. 6 is a perspective view of a structural assembly 600 locked at an angle other than 90 degrees. Assembly 600 is implemented at an angle other than 90 degrees by using a torsion locking block 603 having channels orientated at an angle other than 90 degrees. In this case, a horizontal structural member 602 has a locking interface located approximately at a center point of the length of the member, rather than at one end of the member. Vertical structural member 601 may be identical to structural member 101 described earlier. However, in this embodiment, the ends of structural member 601 are angled according to the angle of block 603 , instead of being cut off at a 90 degree angle. In this case, the angle of construction (linear angle formed by assembled structural members) will be the same angle set by the structural member locking blocks used in the assembly.
[0043] In this example, the frame construction may be that of an interior wall intersecting with a floor that rises at the particular angle set by the torsion locking blocks. Blocking devices 106 are shown in place for fastening to panel coverings described earlier.
[0044] FIG. 7 is a view of a structural member assembly 700 also according to an embodiment of the invention, comprising structural members 701 forming a wall structure, locked along interface 704 to members 702 forming a canted roof, with an optional eave extension as shown in the drawing. Interface 705 is a roof peak with one side of the roof locked to the other side using locking blocks (in this case diamond shaped to match the intersecting shapes of the members) and compression along the peak ridge. In this manner locking blocks may be provided having the appropriate engagement and locking angles for different roof angles, and structural members may be trimmed for length and end shapes to suit.
[0045] FIG. 8A is a perspective view of a torsion locking block 800 according to another embodiment of the present invention. Block 800 has a main body 801 and tongues 802 and 803 extending off of the main body of the block. Block 800 may be formed of a single piece of steel, wood, fiberglass, or some other durable construction material. In one embodiment, main body 801 and tongues 802 and 803 may be separate components joined together to function as one piece. In this embodiment block 800 is of a single contiguous construction.
[0046] In this example, the sides of block 800 that interface with structural members are parallel to the end of each tongue 802 and 803 . That is to say the surfaces lie in the same plane. The back surfaces of tongues 802 and 803 are angled so that the tongues are thicker at the base of main body 801 and thinner at their open ends. Under compression in assembly, the framing may be further strengthened somewhat by the extra footprint provided by tongues 802 and 803 . The width dimension of tongues 802 and 803 is small enough to fit within the inside dimension between rails of the structural members so that the interfacing surface may be seated flush against the middle body of the structural members. A through opening 804 is provided in similar fashion as was described above for accepting a tensioning rod, cable or wire.
[0047] FIG. 8B is a perspective view of a torsion locking block 805 according to yet another embodiment of the present invention. Block 805 has a main body 806 and includes tongues 807 and 808 that interface with structural members in similar fashion as tongues 802 and 803 . Tongues 807 and 808 may be contiguously formed with main body 806 or they may be separate components joined to main body 806 . In this variation, tongues 807 and 808 are of a uniform thickness from the open ends to main body 806 . It is noted herein that block 800 and block 805 may be interchangeable in the same framing assembly without departing from the spirit and scope of the present invention. For example, block 800 may be placed in the portion of the assembly that bears more vertical load while block 805 may be suitable for portions of the assembly where there is less vertical load.
[0048] It will be apparent to one with skill in the art that locking blocks 800 and 805 may both be provided as blocks that present a construction angle that departs from 90 degrees, as has already been discussed above for block 103 . Moreover, the overall thickness of block 103 , block 800 or block 805 may be changed considerably so that structural members may be secured in the assembly having more or less separation, including structural members immediately adjacent or quite widely separated.
[0049] FIG. 9 illustrates a basic box structure 900 using the framing methods and elements of the invention, which may resist loads from any direction and simultaneous loads from multiple directions. Structure 900 , including all of the components described and properly assembled and tensioned may require as few as 4 vertical supports 905 (three are visible in the perspective view) to the ground or to a supporting structure below. In this example, a simple rectangular structure 20 feet wide, 20 feet tall, and 40 feet long uses wooden I-structural members and the framing components described above for floors and roof members spaced at 16 inches on center, with the wall structural members made of the same or similar elements, shapes and spacing but offset from the floor structural members by approximately 8 inches center-to-center.
[0050] The top and floor are connected to the walls of the structure using torsion locking blocks according to an embodiment of this invention with a steel tension rod, wire or cable passing through the assembly at the intersections 901 , 902 , 903 and 904 of horizontal and vertical planes, from one end of the structure to the other end of the structure (40 foot length), and with appropriate tension applied. The top, floor, and walls of the structure are covered by plywood panels in this example, fastened using wood screws or nails, and the blocking components previously described along all of the panel edges completing the structural framing and form. The construction once formed according to the methods and apparatus of the invention is open on each end, although non-load bearing walls may be added including windows, doors, and other openings according to normal construction guidelines and rules. Doors, windows and the like may also be implemented in the long sides of the structure.
[0051] Structure 900 is a basic structure that may pre-fabricated and shipped to a building site, and used there as the basic unit for a home. Structure 900 may be placed on and secured to a foundation, or other simple supports as shown, and a roof and missing walls added by conventional structural techniques, providing a house much more resistant to natural forces than in the current art.
[0052] In one embodiment of the present invention, the components used for the framing may be pre-manufactured and then assembled forming the assemblies during the framing process at a building site. In another embodiment, entire flooring systems, roof systems, ceiling systems and walls may be assembled to specification and then the assemblies may be positioned and further assembled at the corners to secure the complete structure similar in some aspects to assembling a panelized construction. In alternative embodiments similar pre-loaded and pre-fabricated structures according to embodiment of this invention may be provided in a variety of sizes and shapes for a wide variety of purposes, such as storage structures, temporary housing units and the like, and for almost any construction purpose.
[0053] The methods and apparatus of the invention apply to wood construction and steel construction both residential and commercial. Lighter structures may be envisioned that may be fabricated of polymers, fiberglass, aluminum, and other materials depending on load requirements. There are many possibilities. Further it will be apparent to the skilled artisan that there may be many alterations made to the embodiments described as examples in this specification without departing from the spirit and scope of the invention. For example, structural members are shown in examples as I-beam shapes, and engaging geometry of locking blocks comprise edge channels in the blocks to engage the rails of the I-beam shapes. There are, however, a very wide variety of complementary engaging shapes that may be used, all of which are within the spirit and scope of the invention. There are similarly a wide variety of shapes and geometric variations that may be used beyond the simple example described herein. The apparatus and methods of the invention are useful for many sorts of construction where different surfaces may intersect. The invention for these and other reasons is limited only by the breadth of the following claims.
|
A structural assembly has a first set of first elongate structural members alternately spaced apart from a second set of second elongate structural members by locking blocks, the first set defining a first plane and the second set defining a second plane forming an intersection at an angle with the first plane, the structural members and locking blocks defining an assembly of adjoined blocks and structural members at the intersection, and a compressive mechanism spanning the assembly of adjoined blocks and structural members at the intersection. Compressing the adjoined blocks and structural members by the spanning compression mechanism locks the blocks and structural members together in a manner to resist applied forces.
| 4
|
INCORPORATION BY REFERENCE
[0001] This is a division of application Ser. No. 09/824,051 filed Apr. 3, 2001, the disclosure of which is hereby incorporated herein by reference in its entirety.
BACKGROUND
[0002] The present invention relates to a method of making a tank of blown, thermoformed, or rotomolded thermoplastic material. More particularly, but not exclusively, the invention relates to making a fuel tank for a motor vehicle.
[0003] A fuel tank must be designed to prevent fuel being lost through its wall, in particular by diffusing through the thermoplastic material.
[0004] To do this, it is known that the tank can be made from a multi-layer parison that includes a barrier-forming layer constituted by a material having good impermeability to hydrocarbons both in gaseous and in liquid form.
[0005] By way example, such a layer can be based on EVOH.
[0006] In general, a tank made in this way gives satisfaction concerning hydrocarbon emissions.
[0007] It is also necessary to be able to mount attachments such as a fuel pump, a valve, or a pipe, for example, on or in the tank without damaging its barrier-forming layer(s) and without compromising its impermeability of the tank to hydrocarbons.
[0008] U.S. Pat. No. 5,308,427 describes a method of mounting an attachment to the inside of a fuel tank. In that method, a mounting portion in relief is made on the wall of the tank by means of an insert, the parison then covering it during blowing. The attachment has an orifice into which the portion in relief is inserted. The attachment then projects into the inside of the attachment, thereby reducing the height available for performing the function for which the attachment, in particular a valve, is provided, and that can reduce the maximum depth of fuel that can be received by the tank, and thus reduce the capacity of the tank.
SUMMARY
[0009] There exists a need to be able to mount an attachment, in particular a valve, to the inside surface of a tank and as close as possible thereto, for example in order to be able to increase the depth of fuel in the tank.
[0010] The invention seeks to satisfy the above needs in full or in part.
[0011] The invention achieves this by means of a method of making a tank out of blown, thermoformed, or rotomolded thermoplastic material, the method being characterized by the fact that it comprises the following steps:
[0012] making a portion in relief on the inside of the tank, said portion in relief enabling an attachment to be mounted inside the tank and defining a permanent housing for receiving at least a portion of said attachment, the portion in relief being made:
[0013] either by implementing the following steps:
[0014] a) placing at least one insert inside an enclosure;
[0015] b) inserting the material that is to form the wall of the tank inside the enclosure; and
[0016] c) forming the wall of the tank by blowing, thermoforming, or rotomolding, the insert being positioned inside the enclosure in such a manner that while the wall is being formed, it covers the insert at least in part, the insert also being of a shape that is selected in such a manner that said wall, by taking on at least part of the shape of the insert, constitutes said portion in relief;
[0017] or else by mounting a mounting member on the wall of the tank.
[0018] The invention makes it possible to provide a shape for mounting an attachment inside the tank without any need to cut through or pierce the wall of the tank, and this is particularly advantageous when the wall in question includes one or more layer(s) forming a barrier against hydrocarbons.
[0019] Means for mounting an attachment inside the tank are thus obtained in simple and reliable manner without the presence of such mounting means diminishing the leak-proofing of the tank against hydrocarbons.
[0020] The fact that the portion in relief defines a housing makes it possible to mount the attachment, in particular a valve, by engaging it inside the housing, without thereby losing useful height for the purpose of performing the function for which the attachment is provided, and thus without reducing the maximum depth of fuel the tank can accept.
[0021] The attachment need not be a valve, and in particular it could be constituted by a pipe, a filter, a pump, a fuel gauge, or any retaining member.
[0022] The portion in relief can be made on the top wall of the tank.
[0023] When the portion in relief is made by attaching a mounting member to the wall of the tank, it is possible to have greater freedom in the choice of location for the mounting member than when an insert is overmolded.
[0024] When the housing has an end wall, the attachment can come into contact with said end wall after it has been mounted.
[0025] In a particular embodiment, the housing is defined inside an annular wall which can be interrupted or continuous.
[0026] In a variant, the portion in relief can be in the form of two tabs, the housing being defined between the tabs.
[0027] In a particular embodiment, the attachment is put into place inside the housing in an axial direction thereof, which direction can be vertical.
[0028] The portion in relief can be of a shape chosen to enable the attachment to be secured to the wall of the tank by snap-fastening.
[0029] In a variant, the portion in relief can be of a shape selected to enable the attachment to be held to the wall of the tank by friction.
[0030] In both cases, the portion in relief makes it easy to put the attachment into place.
[0031] When the portion in relief is made by implementing steps a) to c), the wall of the tank is advantageously made by blowing a parison placed inside the enclosure.
[0032] When implementing steps a) to c), step a) can precede step b), or vice-versa.
[0033] The shape of the insert can be selected in such a manner as to constitute reinforcement within the wall of the tank, thereby limiting variations in the dimensions of the tank wall.
[0034] The overmolded portion of the insert advantageously presents a shape that is selected in such a manner as to guarantee effective retention in the wall of the tank.
[0035] Thus, in a particular embodiment, the overmolded portion of the insert has two opposite faces that converge towards the outside of the tank.
[0036] In another particular embodiment, the overmolded portion of the insert is annular in shape, having a radially inner surface that diverges towards the outside of the tank.
[0037] Advantageously, the insert is in the form of an interrupted annulus, thus making it possible both to mount an attachment and also to hold it in a predetermined angular position.
[0038] Such a shape serves, in particular, to hold an attachment in a predetermined position when the attachment includes an endpiece suitable for engaging in the passage formed by the interrupted portion of the insert.
[0039] The insert can be kept inside the enclosure while the wall is being formed so that the outside surface of the tank presents a setback in register with the insert. This avoids forming a bulge on the outside wall of the tank which would run the risk of increasing its overall outside dimensions.
[0040] The insert is preferably made of a material having a melting temperature that is higher than that of the material(s) constituting the parison.
[0041] Nevertheless, the insert does not need to be made of a material that is impermeable to hydrocarbons since it is protected by the barrier-forming layer.
[0042] In a particular embodiment, the insert is made of a polyolefin, in particular high-density polyethylene.
[0043] In another particular embodiment, the insert is made of metal.
[0044] After being overmolded, the insert is held captive in the wall of the tank.
[0045] In another implementation invention, the portion in relief is made by applying a mounting member to the wall of the tank by heat-sealing. In which case, the attachment can have elastically deformable tabs suitable for going past an annular bead of the mounting member by elastic deformation.
[0046] Advantageously, the parison has at least one layer of thermoplastic material and a layer that forms a barrier against hydrocarbons.
[0047] In a preferred embodiment, the parison has two layers of thermoplastic material, with a layer forming a barrier against hydrocarbons sandwiched between them. The outer layers thus protect the barrier-forming layer against mechanical damage.
[0048] The tank can be subjected to treatment for forming a barrier against hydrocarbons, in particular treatment by fluorination.
[0049] The invention also provides an insert for implementing the above-specified method.
[0050] The invention also provides a fuel tank comprising a wall of blown thermoplastic material overmolded on at least one insert, the wall covering the insert defining a portion in relief that enables an attachment to be mounted to the body of the tank, said portion in relief including a housing suitable for receiving at least a portion of the attachment.
[0051] The invention also provides a fuel tank comprising a wall of thermoplastic material rotomolded on at least one insert, the wall covering the insert defining a portion in relief enabling an attachment to the mounted to the body of the tank, said portion in relief including a housing suitable for receiving at least a portion of the attachment.
[0052] The invention also provides a fuel tank comprising a wall of thermoplastic material thermoformed on at least one insert, the wall covering the insert defining a portion in relief enabling an attachment to the mounted to the body of the tank, said portion in relief including a housing suitable for receiving at least a portion of the attachment.
[0053] The invention also provides a method of making a tank of blown, thermoformed, or rotomolded thermoplastic material, the method comprising the following steps:
[0054] making a portion in relief on the inside of the tank, said portion in relief enabling an attachment to be mounted inside that tank, the portion in relief being made:
[0055] either by implementing the following steps:
[0056] a) placing at least one insert inside an enclosure;
[0057] b) inserting the material that is to form the wall of the tank inside the enclosure; and
[0058] c) forming the wall of the tank by blowing, thermoforming, or rotomolding, the insert being positioned inside the enclosure in such a manner that while the wall is being formed, it covers the insert at least in part, the insert also being of a shape that is selected in such a manner that said wall, by taking on at least part of the shape of the insert, constitutes said portion in relief;
[0059] or else by mounting a mounting member on the wall of the tank,
[0060] the wall of the tank comprising at least a layer of thermoplastic material and a layer that forms a barrier against hydrocarbons. The portion in relief can then be of the male or of the female type, optionally including a housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0061] Other characteristics and advantages of the present invention will appear on reading the following detailed description of non-limiting embodiments, and on examining the accompanying drawings, in which:
[0062] FIG. 1 is a fragmentary diagrammatic section view of a tank wall including an insert constituting a first embodiment of invention;
[0063] FIG. 2 is a diagrammatic face view seen along arrow II of FIG. 1 ;
[0064] FIG. 3 is a view analogous FIG. 2 showing a second embodiment of invention;
[0065] FIGS. 4 and 5 are diagrams showing two steps in blowing a tank wall inside an enclosure having an insert placed therein;
[0066] FIGS. 6A and 6B are two diagrammatic perspective views of a third embodiment of the invention;
[0067] FIG. 7 is a fragmentary a diagrammatic section view of the tank wall including an insert constituting a fourth embodiment of the invention; and
[0068] FIG. 8 is a fragmentary and diagrammatic axial section view of a mounting member of invention fitted to the tank wall and having an attachment mounted thereto and shown in part.
DETAILED DESCRIPTION OF EMBODIMENTS
[0069] FIG. 1 shows a portion of the wall 1 of the body of a motor vehicle fuel tank.
[0070] This wall 1 has a multi-layer structure, comprising in succession: an outer layer 2 which defines practically the entire outside face 7 of the tank (and made of polyethylene in this example); an intermediate layer 3 forming a barrier against hydrocarbons (and made of EVOH in this example; and an inner layer 4 defining the inside face 8 of the tank (and made of polyethylene in this example).
[0071] In the embodiment described, the multi-layer structure includes a layer of adhesive between each inner or outer layer 4 or 2 and the intermediate layer 3 in order to improve the cohesion of the tank as a whole.
[0072] In this embodiment, an annularly shaped insert 10 is integrated in the wall 1 of the tank.
[0073] The insert 10 it used for providing mounting means 12 defining a housing 18 inside the tank and having an opening 19 of smaller diameter than its end wall 11 .
[0074] The housing 18 is designed to receive a mounting member of the male type (not shown), capable of deforming elastically so as to pass through the opening 19 before engaging in the grooves 18 a and 18 b formed between the opening 19 and the end wall 11 .
[0075] The insert 10 has a radially outer face 10 a which is frustoconical, converging towards the inside of the tank, and a radially inner face 10 b parallel thereto.
[0076] The insert 10 is set back a little from the outside face 7 of the wall 1 , as can be seen in FIG. 1 .
[0077] The converging shape of the radially inner face 10 b provides effective retention of the insert 10 within the wall 1 .
[0078] The insert 10 thus constitutes reinforcement which opposes any variation in the dimensions of the housing 18 , thereby improving the reliability with which the attachment inserted into said housing 18 is mounted.
[0079] In the embodiment of FIGS. 1 and 2 , the insert 10 is in the form of a continuous annulus.
[0080] It can be advantageous to use an insert that is in the form of an interrupted annulus, thereby constituting mounting means 15 of the kind shown in FIG. 3 , having a passage 16 that enables an attachment placed in the housing 18 to be indexed in rotation.
[0081] In other words, the attachment can be mounted inside the tank in a predetermined angular orientation.
[0082] The way in which the insert 10 is integrated in the wall 1 of the tank is described in outline below with reference to FIGS. 4 and 5 .
[0083] The body of the tank is made in conventional manner by blowing a parison 1 ′ inserted into an enclosure 9 .
[0084] The parison 1 ′ has the same multi-layer structure as the wall 1 .
[0085] As shown in FIG. 4 , the insert 10 is put inside the enclosure 9 and is held against its wall prior to blowing the parison 1 ′, using holding means (not shown).
[0086] While the parison 1 ′ is being blown, the wall 1 of the tank takes on its shape and presses itself against the wall of the enclosure 9 , as can be seen in FIG. 5 .
[0087] The wall 1 that results from the blowing is pressed against the insert 10 and follows substantially the same outline, so as to lead to the configuration shown in FIG. 1 .
[0088] It should be observed at that during blowing, the integrity of the barrier-forming intermediate layer 3 is conserved.
[0089] The insert is not limited to a circular annular shape, and it can have a non-circular annular shape, or indeed any other shape.
[0090] FIG. 6A shows an insert 20 that is generally U-shaped having two parallel rectilinear branches 21 a and 21 b whose ends 27 are angled towards each other.
[0091] The base 21 c of the U-shape is perpendicular to the branches 21 a and 21 b.
[0092] The ends 27 leave a passage 26 between them.
[0093] The facing faces 28 of the branches 21 a and 21 b converge going away from the visible main face 29 of the insert 20 .
[0094] The periphery of the insert 20 is chamfered so as to form a slope that makes it possible, while the wall 1 of the tank is being pressed against the insert 20 during blowing, to ensure that the various layers making up the wall are not subjected to excessive stress because of a radius of curvature that is too sharp.
[0095] FIG. 6B shows the wall 1 after it has been overmolded onto the insert 20 .
[0096] The space in the middle of the insert between the branches 21 a , 21 b , and 21 c defines a housing into which mounting means for a valve 24 of a fuel system are snap-fastened, where the portion of the wall that is shown is at the top of the tank.
[0097] The valve 24 has a pipe 25 which engages in the gap formed between the ends 27 .
[0098] By means of its shape, the insert 20 constitutes reinforcement which tends to oppose any variation in the dimensions of the wall 1 covering it, thereby reducing the risk of the valve 24 becoming accidentally detached.
[0099] Naturally, the invention is not limited to the embodiments described above.
[0100] FIG. 7 shows mounting means forming two tabs, made by overmolding two inserts 5 that are placed side by side.
[0101] In the section plane of FIG. 7 , each insert 5 has a cross-section that is trapezoidal in shape, with two opposite side faces 5 a and 5 b which correspond to the short sides of the trapezoid and which converge towards the outside of the tank.
[0102] The face 5 c corresponding to the long face of the trapezoid faces towards the inside of the tank.
[0103] The opposite face 5 d of the insert 5 looks to the outside of the tank.
[0104] It can be seen in FIG. 7 that the wall 1 covers the faces 5 a to 5 c of the inserts 5 and constitutes mounting means 6 .
[0105] The mounting means 6 comprise a housing 6 a defined by the gap between the two inserts 5 and intended to receive a portion of an attachment.
[0106] In a variant, two parallel mounting slideways can be made that define between them a housing that is suitable for receiving a portion of the attachment.
[0107] The attachment can then be put into place by being slid along the direction parallel to the slideways.
[0108] It is possible to use an insert not only to constitute fastening means inside the tank, but also to form fastening means outside the tank.
[0109] By way example, dashed lines in FIG. 1 show an extension of the insert 1 for constituting a collar that can be used on the outside face of the tank to hold a pipe.
[0110] The invention is not limited to forming the wall of a tank by blowing.
[0111] The tank can also be made by rotomolding.
[0112] It is also possible to make the tank by thermoforming, e.g. by vacuum forming, thereby providing two half-shells that are subsequently assembled together.
[0113] The embodiments described above relate to making mounting means by overmolding an insert.
[0114] It would not go beyond the ambit of the present invention to make mounting means by fitting a mounting member to the wall of the tank, in which case the mounting member is not coated in the wall material.
[0115] FIG. 8 shows such a mounting member 40 , secured to the wall of the tank 41 by heat-sealing.
[0116] In the embodiment described, the wall 41 comprises a single-layer structure made of polyethylene.
[0117] The mounting member 40 has a cylindrical tubular wall 42 about an axis X, and a transverse wall 43 situated at quite a short distance from an axial end 44 of the tubular wall 42 .
[0118] The top end 44 of the mounting member 40 is heat-sealed to the tank wall 41 .
[0119] At its bottom end 45 , the tubular wall 42 has an annular bead 50 that is directed radially outwards.
[0120] Together, the tubular wall 42 and the transverse wall 43 define a downwardly open housing 51 suitable for receiving the top portion of an attachment 55 which is constituted in this example by a valve represented solely by its outer skirt 56 about the axis X and by elastically deformable tabs 58 . The tabs bear against the bead 50 .
[0121] The valve 55 also has an inner skirt 60 , likewise on the axis X, and engaged in the tubular wall 42 so as to bear against the transverse wall 43 .
[0122] The valve 55 is provided with a coupling endpiece 65 that extends sideways, passing through the inner and outer skirts 60 and 56 .
[0123] The valve 55 is put into place on the safety member 40 by snap-fastening along the axis X, the tabs 58 deforming elastically to go past the bead 50 .
|
A method provides a tank out of blown, thermoformed, or rotomolded thermoplastic material with a portion in relief for enabling mounting of an attachment inside the tank. The method includes making the portion in relief on the inside of the tank, the portion in relief enabling an attachment to be mounted inside the tank. The portion in relief is made by mounting a mounting member on the wall of the tank. Preferred mounting is by heat-sealing. The wall of the tank includes at least a layer of thermoplastic material and preferably includes a layer that forms a barrier against hydrocarbons. A tank with a portion in relief mounted on an inside wall is also provided.
| 1
|
CROSS-REFERENCE
[0001] The present application is a continuation application of U.S. patent application Ser. No. 14/791,314, entitled “Multi-Element Cover for a Multi-Camera Endoscope” and filed on Jul. 3, 2015, which is a continuation application of U.S. patent application Ser. No. 13/984,028, of the same title, filed on Aug. 22, 2013, and issued as U.S. Pat. No. 9,101,266 on Aug. 11, 2015, which is a national stage entry application of PCT Application Number PCT/IL2012/050037, of the same title and filed on Feb. 6, 2012, which relies on U.S. Provisional Patent Application No. 61/439,948, filed on Feb. 7, 2011, for priority. All of the aforementioned applications are herein incorporated by reference.
FIELD
[0002] Embodiments of the disclosure relate to a multi element cover to a tip section of a multi-camera endoscope.
BACKGROUND
[0003] Endoscopes have attained great acceptance within the medical community, since they provide a means for performing procedures with minimal patient trauma, while enabling the physician to view the internal anatomy of the patient. Over the years, numerous endoscopes have been developed and categorized according to specific applications, such as cystoscopy, colonoscopy, laparoscopy, upper GI endoscopy and others. Endoscopes may be inserted into the body's natural orifices or through an incision in the skin.
[0004] An endoscope is usually an elongated tubular shaft, rigid or flexible, having a video camera or a fiber optic lens assembly at its distal end. The shaft is connected to a handle, which sometimes includes an ocular for direct viewing. Viewing is also usually possible via an external screen. Various surgical tools may be inserted through a working channel in the endoscope for performing different surgical procedures.
[0005] Endoscopes, such as colonoscopes, that are currently being used, typically have a front camera for viewing the internal organ, such as the colon, an illuminator, a fluid injector for cleaning the camera lens and sometimes also the illuminator and a working channel for insertion of surgical tools, for example, for removing polyps found in the colon. Often, endoscopes also have fluid injectors (“jet”) for cleaning a body cavity, such as the colon, into which they are inserted. The illuminators commonly used are fiber optics which transmit light, generated remotely, to the endoscope tip section. The use of light-emitting diodes (LEDs) for illumination is also known.
[0006] Among the disadvantages of such endoscopes, are their limited field of view and their complicated packing of all the required elements, such as electronics and fiber optics together with fluid carrying elements in the small sized endoscope tip section. Other problem of the existing endoscopes is the difficult assembling of the gentle electronic components, which are often damaged by the assembling process itself. Another problem of the existing endoscopes is the complicated sealing of the parts, specifically in the tip section of the endoscope. Sealing of the tip section remains a challenge particularly due to the complex environment in which the endoscope is intended to operate.
[0007] There is thus a need in the art for endoscopes, such as colonoscopes, that allow a broader field of view and also enable the efficient packing, assembling and sealing of all necessary elements in the tip section, while maintaining their function.
[0008] The foregoing examples of the related art and limitations related therewith are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the figures.
SUMMARY
[0009] The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, not limiting in scope.
[0010] According to some embodiments, there is provided a tip section of a multi-camera endoscope, the tip section comprising: a front-pointing camera and a discrete front illuminator associated therewith; one or more side-pointing cameras and one or more discrete side illuminators associated therewith; and a multi component cover configured to cover the inner parts of the tip section.
[0011] According to some embodiments, there is provided a tip section of a multi-camera endoscope, the tip section comprising: a front looking camera and a front discrete illuminator to essentially illuminate the Field Of View (FOV) of the front looking camera; a right side looking camera and a right discrete illuminator to essentially illuminate the FOV of the right side looking camera; a left side looking camera and a left discrete illuminator to essentially illuminate the FOV of the left side looking camera; and a multi component cover configured to cover and seal the tip section such as to essentially prevent entry of fluids from the environment of the endoscope to inner parts of the tip section.
[0012] According to some embodiments, the multi component cover comprises: a front-side component configured to cover a front part and a side part of the tip section; and a side component configured to cover another side part of the tip section, wherein the front-side component and the side component are configured to abut to cover the tip section. The front-side component may be configured to cover the front part and a right side part of the tip section and wherein the side component is configured to cover a left side part of the tip section. The front-side component may be configured to cover the front part and a left side part of the tip section and wherein the side component is configured to cover a right side part of the tip section.
[0013] According to some embodiments, the multi component cover comprises: a front component configured to cover a front part; a right side component configured to cover a right side part of the tip section; and a left side component configured to cover a left side part of the tip section; wherein the front, right side and left side components are configured to abut to cover the tip section.
[0014] According to some embodiments, the multi component cover comprises: a main component configured to cover the majority of the tip section; and a removable window component configured to cover a window opening located on the main component, wherein the removable window component is configured to allow access to an inner part of the tip section without removing the main component.
[0015] According to some embodiments, the multi component cover comprises: a distal component configured to cover a distal part of the tip section; and a proximal component configured to cover a proximal part of the tip section, wherein the distal component and the proximal component are configured to abut to cover the tip section. According to some embodiments, the distal component may have a shape of a cylinder having a side wall and a front face, the front face is configured to cover a front part of the tip section and the proximal component has a shape of a cylinder having a side wall. According to some embodiments, the distal component may be configured for assembling over an inner part of the tip section from a distal part of the tip section and wherein the proximal component is configured for assembling over the inner part of the tip section from a proximal part of the tip section, such that the distal component and the proximal component are configured to join each other along a connection line, (which may be essentially perpendicular to the length of the tip section, for example, along an imaginary line extended between the two side cameras), such that the assembling does not cause damage to the a right/left side looking cameras or optical assemblies thereof.
[0016] The multi component cover further comprises optical windows for one or more of: the front discrete illuminator, the right discrete illuminator, and the left discrete illuminator.
[0017] The multi component cover may further comprise openings for one or more of: the front looking camera and/or an optical assembly thereof, the right side looking camera and/or an optical assembly thereof, and the left side looking camera and/or an optical assembly thereof.
[0018] The multi component cover may further comprise a fluid channeling component adapted to channel fluid for insufflations and/or irrigation. The fluid channeling component may be a unitary component comprising a front fluid channel leading to a front opening at a distal end of the unitary fluid channeling component, for cleaning one or more front optical elements of the tip section, and a side fluid channel leading to a left side opening and to a right side opening in the unitary fluid channeling component, for cleaning side optical elements of the tip section. The unitary fluid channeling component further comprises a working channel adapted for the insertion of a medical tool. The unitary fluid channeling component further comprises a jet fluid channel adapted to clean a body cavity into which the endoscope is inserted.
[0019] According to some embodiments, the multi component cover may further include openings for one or more of: a front I/I injector and/or a nozzle thereof, a side I/I injector and/or a nozzle thereof, a jet fluid channel, and a working channel.
[0020] According to some embodiments, the front looking camera, the front discrete illuminator, the right side looking camera, the right discrete illuminator, the left side looking camera, and the left discrete illuminator are configured to be installed on a single electronic circuit board.
[0021] According to some embodiments, the tip section has a diameter of about 17 mm or less. According to some embodiments, the tip section has a diameter of about 12 mm or less. According to some embodiments, the tip section has a diameter of about 10 mm or less. According to some embodiments, the tip section has a diameter of about 7 mm or less.
[0022] According to some embodiments, there is provided a method for assembling a multi component cover on a tip section of a multi-camera endoscope, the method comprising: installing one or more optical windows on a first part of a multi component cover; installing the first part of an inner part of a tip section; installing one or more optical windows on a second part of the multi component cover; and installing the second part of the inner part of the tip section.
[0023] According to some embodiments, the first part of the multi component cover comprises: a front-side component configured to cover a front part and a side part of the tip section; and the second part of the multi component cover comprises: a side component configured to cover another side part of the tip section, wherein the front-side component and the side component are configured to abut to cover the tip section. The front-side component may be configured to cover the front part and a right side part of the tip section and wherein the side component is configured to cover a left side part of the tip section. The front-side component may be configured to cover the front part and a left side part of the tip section and wherein the side component is configured to cover a right side part of the tip section.
[0024] According to some embodiments, the first part of the multi component cover comprises a front component configured to cover a front part; wherein the second part of the multi component cover comprises a right side component configured to cover a right side part of the tip section; wherein the a third part of the multi component cover comprises a left side component configured to cover a left side part of the tip section; and wherein the front, right side and left side components are configured to abut to cover the tip section.
[0025] According to some embodiments, the first part of the multi component cover comprises a main component configured to cover the majority of the tip section; and wherein the second part of the multi component cover comprises a removable window component configured to cover a window opening located on the main component, wherein the removable window component is configured to allow access to an inner part of the tip section without removing the main component.
[0026] According to some embodiments, the first part of the multi component cover comprises a distal component configured to cover a distal part of the tip section; and wherein the second part of the multi component cover comprises a proximal component configured to cover a proximal part of the tip section, wherein the distal component and the proximal component are configured to abut to cover the tip section. The distal component may have a shape of a cylinder having a side wall and a front face, the front face is configured to cover a front part of the tip section and the proximal component has a shape of a cylinder having a side wall.
[0027] According to some embodiments, any one of the parts (components) of the multi component cover may include a cannel/cavity, for example, along one or more edges of the part (component), on an external and/or internal part of the part (component). The cannel/cavity may be configured to contain one or more adhesives, such as glue, for connecting the parts (components) to each other and thus allowing better sealing of the tip cover.
[0028] According to some embodiments, there is provided herein an endoscope comprising the tip section as described herein. According to some embodiments, there is provided herein a colonoscope comprising the tip section as described herein.
[0029] According to some embodiments, there is provided herein a multi-camera endoscope, such as a colonoscope, comprising the tip section disclosed herein. According to some embodiments, the tip section of an endoscope (such a colonoscope) is the most distal part of the endoscope which terminates the endoscope. The tip section is turnable by way of a bending section connected thereto.
[0030] More details and features of the current invention and its embodiments may be found in the description and the attached drawings.
[0031] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below. In case of conflict, the patent specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.
BRIEF DESCRIPTION OF THE FIGURES
[0032] Exemplary embodiments are illustrated in referenced figures. Dimensions of components and features shown in the figures are generally chosen for convenience and clarity of presentation and are not necessarily shown to scale. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than restrictive. The figures are listed below:
[0033] FIG. 1 a schematically depicts an isometric view of a tip section of an endoscope (including an electronic circuit board carrying cameras and illumination sources, and fluid channeling component), having a multi component tip cover (shown in an exploded view), according to an exemplary embodiment of the current invention;
[0034] FIG. 1 b schematically depicts an isometric view of the tip section of FIG. 1 a , having an assembled multi component tip cover, according to some exemplary embodiments of the current invention;
[0035] FIG. 2 schematically depicts an isometric view of a tip section of an endoscope (including an electronic circuit board carrying cameras and illumination sources, and a fluid channeling component), having a multi component tip cover (shown in an exploded view), according to an exemplary embodiment of the current invention;
[0036] FIG. 3 schematically depicts an exploded view of a multi component tip cover, according to an exemplary embodiment of the current invention;
[0037] FIG. 4 a schematically depicts an isometric view of a tip section of an endoscope (including an electronic circuit board carrying cameras and illumination sources, and a fluid channeling component), having a multi component tip cover (shown in an exploded view), according to an exemplary embodiment of the current invention;
[0038] FIG. 4 b schematically depicts an isometric view of the tip section of FIG. 4 a , having a multi component tip cover (partially in an exploded view), according to an exemplary embodiment of the current invention; and
[0039] FIG. 4 c schematically depicts an isometric view of the tip section of FIGS. 4 a - b having an assembled multi component tip cover, according to an exemplary embodiment of the current invention.
DETAILED DESCRIPTION
[0040] While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced be interpreted to include all such modifications, permutations, additions and sub-combinations as are within their true spirit and scope.
[0041] In the description and claims of the application, each of the words “comprise” “include” and “have”, and forms thereof, are not necessarily limited to members in a list with which the words may be associated.
[0042] Reference is now made to FIG. 1 a , which schematically depicts an isometric view of a tip section of an endoscope (including an electronic circuit board carrying cameras and illumination sources, and a fluid channeling component), having a multi component tip cover (shown in an exploded view), according to an exemplary embodiment of the current invention and to FIG. 1 b , which schematically depicts an isometric view of the tip section of FIG. 1 a , having an assembled multi component tip cover, according to some exemplary embodiments of the current invention.
[0043] Tip section 100 generally includes an inner part 110 which includes electronics (such as cameras, circuit board such as electronic circuit board 400 , illumination sources, such as LEDs etc.), fluid channels (such as fluid channeling component 600 ) and a multi-element tip cover 700 . Multi-element tip cover 700 is designed to fit over the inner parts of the tip section 100 , and to provide protection to the internal components in the inner part. Multi-element tip cover 700 includes, according to this embodiment, three parts: a front component 710 configured to cover a front part of the tip section; a right side component 730 configured to cover a right side part of the tip section; and a left side component 750 configured to cover a left side part of the tip section, wherein the front, right side and left side components are configured to abut each other to cover the tip section, in such way that they cover essentially all inner parts of the tip section.
[0044] Front component 710 includes hole 736 configured to align with (and accommodate) front optical assembly 236 of forwards looking camera 116 ; optical windows 242 a , 242 b and 242 c of LEDs 240 a , 240 b and 240 c ; distal opening 340 of a working channel 640 ; distal opening 344 of a jet fluid channel 644 ; and irrigation and insufflation (I/I) injector 346 having a nozzle 348 (aligning with opening 664 of fluid channeling component 600 ).
[0045] Left side component 750 includes hole 756 b configured to align with (and accommodate) side optical assembly 256 b of side looking camera 220 b ; optical windows 252 a and 252 b of LEDs 250 a and 250 b on both sides of optical assembly 256 b ; side I/I injector 266 b adapted to align with side I/I opening 666 b of fluid component 600 . Also seen in FIGS. 1 a and b are nozzles 267 a and b for right side I/I injector (not shown) and left side I/I injector 266 b respectively.
[0046] Right side component 730 includes similar elements (not shown) as left side component 750 .
[0047] Left side component 750 and right side component 730 are each in a shape of essentially half a cylinder (without top and bottom).
[0048] Front component 710 has essentially a cup shape having two opposing arms 712 and 714 extending perpendicularly to the cup bottom (which may also be referred to as the cup's front face) and protruding from the cup edges. Upon assembling of the tip cover components, front component 710 may be installed first, and then the side components such that their long edges meet each other on both sides over arms 712 and 714 to assure sealing ( FIG. 1 b ). Adhesives, such as glue, may be added, for example, in cavities 716 (along the external parts of the edges of component 710 ), 718 (along the internal edges of component 730 ) and 720 (along the internal edges of component 750 ) to allow complete sealing of tip section 100 .
[0049] Multi-element tip covers according to embodiments of the invention, such as multi-element tip cover 700 or any other multi-element tip cover as disclosed herein, solves a significant problem that exists in the art when attempts are made to pack all necessary components into the small inner volume of an endoscope tip and to cover and seal these components. Regular cup shaped tip covers are used for standard tips having just one front camera. However, when standard cup shaped tip covers are used to cover the multi-camera tip, protruding inner tip elements, such as lenses or other parts of the side optical assemblies, are often damaged during the sliding of the cover over them. Using a multi-element tip cover may solve this problem. In addition, a multi-element tip cover assists in aiming its holes/openings/windows exactly at their right place over the corresponding tip inner elements. This is almost impossible using a unitary piece cover. Moreover, separately sealing each one of the elements of the multi-element tip cover improves the overall sealing of the tip due to better access to each element (for example an optical window) compared to the limited access of the same element in a unitary piece cover, such as a cup shaped cover. Separately sealing (and optionally checking for satisfactory sealing) of each one of the elements of the multi-element tip cover may be performed prior to assembling of the cover. This may also improve the sealing of the tip.
[0050] According to an embodiment of the current invention, tip section 100 of an endoscope comprises at least a forwards looking camera and at least one side looking camera. Tip section 100 is turnable by way of a flexible shaft (not shown) which may also be referred to as a bending section, for example a vertebra mechanism).
[0051] In some embodiments, the front-looking camera and/or any of the side-looking cameras comprises a Charge Coupled Device (CCD) or a Complementary Metal Oxide Semiconductor (CMOS) image sensor.
[0052] It is noted that the term “endoscope” as mentioned to herein may refer particularly to a colonoscope, according to some embodiments, but is not limited only to colonoscopes. The term “endoscope” may refer to any instrument used to examine the interior of a hollow organ or cavity of the body.
[0053] Tip section 100 may include front optical assembly 236 of forwards looking camera 116 . Optical axis of forwards looking camera 116 is substantially directed along the long dimension of the endoscope. However, since forward looking camera 116 is typically a wide angle camera, its Field Of View (FOV) may include viewing directions at large angles to its optical axis. It should be noted that number of illumination sources such as LEDs used for illumination of the FOV may vary (for example, 1-5 LEDs may be used on a front face of tip section 100 ). Distal opening 340 of a working channel 640 is also located on the front face of tip section 100 , such that a surgical tool inserted through working channel tube, and through the working channel 640 in the endoscope's tip section 100 and deployed beyond the front face may be viewed by forwards looking camera 116 .
[0054] Distal opening 344 of a jet fluid channel 644 is also located on the front face of tip section 100 . Distal opening 344 of a jet fluid channel 644 may be used for providing high pressure jet of fluid such as water or saline for cleaning the walls of the body cavity.
[0055] Also located on the front face of tip section 100 is an irrigation and insufflation (I/I) injector 346 having a nozzle 348 aimed at front optical assembly 236 . I/I injector 346 may be used for injecting fluid (liquid and/or gas) to wash contaminants such as blood, feces and other debris from front optical assembly 236 of forwards looking camera 116 . Optionally, the same injector is used for cleaning front optical assembly 236 and one, two or all of optical windows 242 a , 242 b and 242 c . I/I injector 346 may be fed by fluid such as water and/or gas which may be used for cleaning and/or inflating a body cavity.
[0056] Visible on a left side of tip section 100 is the side camera (side looking camera) element 256 b of side looking camera 220 b and optical windows 252 a and 252 b of LEDs 250 a and 250 b for camera 220 b . A second side looking camera (not shown) is positioned on the right side of the tip and can be similar to camera 220 b . Optical axis of the second side looking camera is substantially directed perpendicular to the long dimension of the endoscope. Optical axis of side looking camera 220 b is substantially directed perpendicular to the long dimension of the endoscope. However, since side looking camera 220 b and the second side looking camera are typically wide angle cameras, their fields of view may include viewing directions at large angles to their optical axes.
[0057] Side I/I injector 266 b having a nozzle 267 b aimed at side optical assembly 256 b may be used for injecting fluid to wash contaminants such as blood, feces and other debris from side optical assembly 256 b of side looking camera. The fluid may include gas which may be used for inflating a body cavity. Optionally, the same injector is used for cleaning both side optical assembly 256 b and optical windows 252 a and/or 252 b . It is noted that according to some embodiments, the tip may include more than one window and LEDs, on the side and more than one window and LEDs in the front (for example, 1-5 windows and two LEDs on the side). Similar configuration of I/I injector and nozzle (not shown) exists for cleaning the optical assembly and optical windows (not shown) located on the other side of tip 100 . The I/I injectors are configured to clean all or a part of these windows/LEDs. In various embodiments, left side I/I injector 266 b , right side I/I injector (not shown), and front side I/I injector 344 are fed from the same channel.
[0058] It is noted that the right side wall (not shown) and left side wall 362 have a form of an essentially flat surface which assists in directing the cleaning fluid injected from the right side I/I injector (not shown) and the left side injector 266 b towards the right side optical assembly and windows and the left side optical assembly 256 b and optical windows 252 a and/or 252 b respectively. Lack of such flat surface may result in dripping of the cleaning fluid along the curved surface of tip section 100 of the endoscope without performing the desired cleaning action.
[0059] It should be noted that while only one side looking camera can be seen in FIGS. 1 a and b , preferably at least two side looking cameras are located within tip section 100 . When two side looking cameras are used, the side looking cameras are preferably installed such that their field of views are substantially opposing. However, different configurations and number of side looking cameras are possible within the general scope of the current invention.
[0060] According to some embodiments, the circuit board used for carrying electronic components, such as cameras and/or LEDs, may be a flexible circuit board that may consume less space and leaves more volume for additional necessary features. The flexibility of the board adds another dimension in space that can be used for components positioning.
[0061] The use of a flexible circuit board, according to embodiments of the invention, can significantly increase reliability of the electric modules connection thereto as no wires are for components connectivity. In addition, according to some embodiments, the components assembly can be machined and automatic.
[0062] The use of a flexible circuit board, according to some embodiments of the invention, may also allow components (parts) movement and maneuverability during assembly of the camera head (tip of the endoscope) while maintaining a high level of reliability. The use of the circuit board, according to some embodiments of the invention, may also simplify the (tip) assembling process.
[0063] According to some embodiments, a flexible circuit board may be connected to the control unit via multi wire cable; this cable may be welded on the board in a designated location, freeing additional space within the tip assembly and adding flexibility to cable access. Assembling the multi wire cable directly to the electrical components was a major challenge which is mitigated by the use of the flexible board according to embodiments of the invention.
[0064] Reference is now made to FIG. 2 , which schematically depicts an isometric view of a tip section of an endoscope (including an electronic circuit board carrying cameras and illumination sources, and a fluid channeling component), having a multi component tip cover (shown in an exploded view), according to an exemplary embodiment of the current invention. Tip section 200 generally includes an inner part 210 which may be similar to inner part 110 of tip section 100 of FIGS. 1 a - b and a multi-element tip cover 800 . Multi-element tip cover 800 is designed to fit over the inner parts of the tip section 200 , and to provide protection to the internal components in the inner part. Multi-element tip cover 800 includes, according to this embodiment, a main component 830 configured to cover the majority of the tip section; and a removable window component 850 configured to cover a window opening 860 located on main component 830 , such that removable window component 850 is configured to allow access to an inner part 210 of tip section 200 without removing main component 830 . This may allow fixing or replacing one of the components of inner part 210 (such as a LED, an optical element or any other element) without removing main component 830 and damaging the packing and sealing of tip section 200 .
[0065] Main component 830 has essentially a cup shape having a front face part configured to cover the front face of tip section 200 and cup edges configured to cover the side surface of tip section 200 .
[0066] Main component 830 may further includes front and side holes, openings, windows and surfaces similar to those of multi-component cover 700 of FIGS. 1 a and b.
[0067] Reference is now made to FIG. 3 , which schematically depicts an exploded view of a multi component tip cover, according to an exemplary embodiment of the current invention. Multi-element tip cover 900 is designed to fit over the inner part (not shown) of a tip section and to provide protection to the internal components in the inner part. Multi-element tip cover 900 includes, according to this embodiment, a front-side component 930 configured to cover a front part and a side part of the tip section and a side component 950 configured to cover another side part of the tip section, wherein front-side component 930 and side component 950 are configured to abut to cover the tip section.
[0068] Reference is now made to FIGS. 4 a - c . FIG. 4 a schematically depicts an isometric view of a tip section of an endoscope (including an electronic circuit board carrying cameras and illumination sources, an electronic circuit board holder, a fluid channeling component), having a multi component tip cover (shown in an exploded view), according to an exemplary embodiment of the current invention. FIG. 4 b schematically depicts an isometric view of the tip section of FIG. 4 a , having a multi component tip cover (partially in an exploded view), according to an exemplary embodiment of the current invention. FIG. 4 c schematically depicts an isometric view of the tip section of FIGS. 4 a - b having a multi component tip cover, according to an exemplary embodiment of the current invention.
[0069] Tip section 1000 generally includes an inner part 1100 which includes electronics (such as cameras, circuit board, LEDs etc.), fluid channels (such as fluid channeling component 1600 ) and a multi-element tip cover 1010 . Multi-element tip cover 1010 is designed to fit over the inner parts of the tip section 1000 , and to provide protection to the internal components in the inner part. Multi-element tip cover 1010 includes, according to this embodiment, two parts: a distal component 1050 configured to cover a distal part of the tip section and a proximal component 1030 configured to cover a proximal part of the tip section, wherein the distal component and the proximal component are configured to abut to cover the tip section. Distal component 1050 has a shape of a cylinder having a side wall 1052 and a front face 1054 , front face 1054 is configured to cover a front part 1102 of inner part 1100 of tip section 1000 and proximal component 1030 has a shape of a cylinder having a side wall 1032 without a top or a bottom configured to cover a proximal part 1104 of inner part 1100 of tip section 1000 .
[0070] Distal component 1050 includes on front face 1054 thereof hole 1056 configured to align with front optical assembly 1236 of forwards looking camera 1116 ; optical windows 1242 a , 1242 b and 1242 c of LEDs 1240 a , 1240 b and 1240 c ; distal opening 1340 of a working channel 1640 ; distal opening 1344 of a jet fluid channel 1644 ; and I/I injector 1346 (aligning with opening 1664 of Fluid channeling component 1600 ).
[0071] Distal component 1050 further includes on side wall 1052 thereof optical windows 1252 a of LED 1250 a and on an opposing side of side wall 1052 another optical window of another LED (not shown).
[0072] Distal component 1050 further includes on the edge of side wall 1052 thereof a recess 1756 ′ (essentially in a shape of half a hole) configured to accommodate (along with a recess 1756 ″ on the edge of side wall 1032 of proximal component 1030 ) optical assembly 1256 b of side looking camera 1120 b . On an opposing side of side wall 1052 there may be a similar recess (not shown) to accommodate (along with another recess on the edge of an opposing side of side wall 1032 of proximal component 1030 ) an optical assembly (not shown) of a side looking camera (not shown) located on the other side of inner part 1100 .
[0073] Proximal component 1030 includes on side wall 1032 thereof optical windows 1252 b of LED 1250 b and on an opposing side of side wall 1032 another optical window (not shown) of another LED (not shown).
[0074] Proximal component 1030 further includes on the edge of side wall 1032 thereof a recess 1756 ″ (essentially in a shape of half a hole) configured to accommodate (along with recess 1756 ′ on the edge of side wall 1052 of distal component 1050 ) optical assembly 1256 b of side looking camera 1120 b . On an opposing side of side wall 1032 there is a similar recess 1756 a ″ to accommodate (along with another recess on the edge of an opposing side of side wall 1032 of proximal component 1050 ) an optical assembly (not shown) of a side looking camera (not shown) located on the other side of inner part 1100 .
[0075] Proximal component 1030 further includes side I/I injector 1266 b adapted to align with side I/I opening 1666 b.
[0076] Other parts of inner part 1100 of tip section 1000 may generally be similar to inner part 1100 of tip section 100 of FIG. 1 a - b.
[0077] The method of assembling tip section 1000 over inner part 1100 may include assembling distal component 1050 from the distal part of tip section 1000 , assembling proximal component 1030 from the proximal part of tip section 1000 and joining distal component 1050 and proximal component 1030 along their edges (line 1500 ) such that none of the tip cover components slides over the optical assemblies of the side looking cameras.
[0078] Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims. All publications, patents and patent applications mentioned in this specification are herein incorporated in their entirety by reference into the specification, to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated herein by reference. In addition, citation or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention.
|
There is provided herein a tip section of a multi-camera endoscope, the tip section comprising: a front looking camera and a front discrete illuminator to essentially illuminate the Field Of View (FOV) of said front looking camera; a right side looking camera and a right discrete illuminator to essentially illuminate the FOV of said right side looking camera; a left side looking camera and a left discrete illuminator to essentially illuminate the FOV of said left side looking camera; and a multi component cover configured to cover and seal said tip section such as to essentially prevent entry of fluids from the environment of said endoscope to inner parts of said tip section.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of application Ser. No. 08/579,614, now U.S. Pat. No. 5,746,035, filed Dec. 26, 1995, issued May 5, 1998 and entitled PARTITION SYSTEM. The present application further is related to the following commonly assigned U.S. Patents: U.S. Pat. No. 5,746,034, filed Dec. 30, 1994, issued May 5, 1998 and entitled PARTITION SYSTEM; U.S. Pat. No. 5,740,650, filed on Dec. 26, 1995, issued Apr. 12, 1998 and entitled PARTITION SYSTEM; U.S. Pat. No. 5,784,843, filed Dec. 30, 1994, issued Jul. 28, 1998 and entitled INTEGRATED PREFABRICATED FURNITURE SYSTEM FOR FITTING-OUT OPEN PLAN BUILDING SPACE; U.S. Pat. No. 5,809,708, filed May 25, 1995, issued Sep. 22, 1998 and entitled INTEGRATED PREFABRICATED FURNITURE SYSTEM FOR FITTING-OUT OPEN PLAN BUILDING SPACE; U.S. Pat. No. 5,816,001, filed Jul. 26, 1996, issued Oct. 6, 1998 and entitled PARTITION CONSTRUCTION INCLUDING INTERCONNECTION SYSTEM AND REMOVABLE COVERS; U.S. Pat. No. 5,890,325, filed Aug. 22, 1996, issued Apr. 6, 1999 and entitled RECONFIGURABLE SYSTEM FOR SUBDIVIDING BUILDING SPACE AND HAVING MINIMAL FOOTPRINT; and U.S. Pat. No. 5,943,834, filed Nov. 13, 1997, issued Aug. 31, 1999 and entitled PARTITION CONSTRUCTION.
BACKGROUND OF THE INVENTION
The present invention relates to partition systems supported on floor channels where the floor channel stably engages a floor, and more particularly relates to a partition system having a partition attached to a floor channel where the floor channel includes attachment points for interconnecting furniture units, such as additional partitions or accessories, to the partition in locations in front of the partition.
Portable partition systems for open office spaces, and other similar settings, are well known in the art. Individual partition panels are interconnected in different configurations to form separate offices, work stations or work settings. The partition panels are extremely durable, and can be readily disassembled and reassembled into alternative configurations to meet the ever-changing needs of the user. Examples of such partition systems are provided in U.S. Pat. Nos. 3,822,146; 3,831,330; and 4,144,924, which are owned by Steelcase Inc., the assignee of the present application.
The finishing or fitting-out of building spaces for offices, medical treatment facilities, and other similar environments has become a very important aspect of effective space planning and layout. Work patterns, technology, and business organizations are constantly evolving and changing. The building space users require products which facilitate change at lower costs. Space planning is no longer a static problem. Changing technology and changing work processes demand that a design and installation be able to support and anticipate change. However, often the existing partition systems are limited in their ability to be reconfigured, thus limiting the number and size of different office arrangements that can be constructed, and limiting the speed with which changes can be made.
Consequently, a fully integrated prefabricated furnishing system has been developed to finish or fit-out both new and existing open plan building spaces. One requirement of this integrated furnishing system is a freestanding portable partition system that has enhanced utility carrying capabilities while still facilitating quick and accurate reconfiguration. Concurrently, it is desired to provide a panel connection system having increased flexibility for interconnecting reconfigurable partition panels in office layouts. For example, a partition panel connection system is desired that allows use of standardized base partition panels and that facilitates accurate positioning of the partition panels even where the dimensions of the office layouts are not multiples of the base partition panel width dimension. Additional functionality of the connection system is also desired, such as to permit removing a partition panel from attachment to another panel without having to disassemble both panels. Concurrently, an attachment system is needed that permits quick attachment of a “fin” partition perpendicularly to a main run of “spine” partitions, where the attachment system provides secure attachment but does not require multiple parts and does not detract from the overall appearance of the partition system.
Thus, a wall construction solving the aforementioned problems and providing the aforementioned functionalities is desired.
SUMMARY OF THE INVENTION
In one aspect of the present invention, a partition system for subdividing a building space includes a partition having a horizontal frame member defining a first horizontal row of discrete attachment points for supporting a furniture unit, and a floor channel configured to stably engage a floor surface and supporting the partition. The floor channel defines a second horizontal row of discrete attachment points corresponding to the first horizontal row of discrete attachment points for supporting the furniture unit.
In another aspect, a partition system includes a partition having a bottom, and a floor channel engaging the bottom and adapted to stably support the partition on a floor surface, the floor channel including a horizontal row of discrete attachment points extending horizontally along the floor channel in a location generally under the partition for supporting a furniture unit adjacent the partition.
In another aspect, an elongated floor channel for supporting a partition includes a bottom flange configured to stably engage a floor surface, a second flange configured to engage and support a partition, and side flanges located on opposing sides of the bottom flange that each define a horizontal row of discrete attachment points configured to receive brackets for connecting a furniture unit to the floor channel. The arrangement allows the furniture unit to be supported adjacent the floor surface in a selected off-module position along the floor channel.
In another aspect, a method comprises steps of providing a floor channel having a first horizontal row of discrete attachment points, providing a spine partition having a second horizontal row of discrete attachment points, and providing a second partition. The method further includes supporting the spine partition on the floor channel with the first and second horizontal row of discrete attachment points spaced vertically apart, and attaching the second partition to selected points in the first and second horizontal row of discrete attachment points.
These and other advantages of the invention will be further understood and appreciated by those skilled in the art by reference to the following written specification, claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an integrated prefabricated furniture system, which includes a partition panel and related system embodying the present invention;
FIG. 2 is a perspective view of a partition panel embodying the present invention;
FIG. 3 is an exploded, perspective view of the partition panel wherein portions thereof have been broken away to reveal internal construction;
FIG. 4 is an exploded, perspective view of a base panel portion of the partition panel having a frame with removable cover panels;
FIG. 5 is a fragmentary, rear elevational view of the cover panel showing a mounting clip thereon;
FIG. 6 is a fragmentary, top plan view of the cover panel shown in FIG. 5;
FIG. 7 is a side elevational view of the mounting clip;
FIG. 8 is a fragmentary, vertical cross-sectional view of a cover panel shown mounted on the base panel frame;
FIG. 9 is a fragmentary, top plan view of the base panel frame;
FIG. 10 is a fragmentary, front elevational view of the base panel frame;
FIG. 11 is a side elevational view of the base panel frame;
FIG. 12 is a fragmentary, top plan view of a horizontal stringer portion of the base panel frame;
FIG. 13 is a fragmentary, bottom plan view of the horizontal stringer shown in FIG. 12;
FIG. 14 is a fragmentary, front elevational view of the stringer shown in FIGS. 12 and 13;
FIG. 15 is a fragmentary, rear elevational view of the horizontal stringer shown in FIGS. 12-14.
FIG. 16 is an exploded, perspective view of a stacker panel portion of the partition panel having a frame with removable cover panels;
FIG. 17 is a fragmentary, top plan view of the stacker panel frame;
FIG. 18 is a fragmentary, front elevational view of the stacker panel frame;
FIG. 19 is a fragmentary, bottom plan view of the stacker panel frame;
FIG. 20 is a side elevational view of the stacker panel frame;
FIG. 21 is a fragmentary, front elevational view of a stacker panel frame mounted on a base panel frame;
FIG. 22 is an enlarged, fragmentary front elevational view of a connection between the stacker panel frame and base frame shown in FIG. 21;
FIG. 23 is a side elevational view of the interconnected base frame and stacker panel frame shown in FIG. 21;
FIG. 24 a is a fragmentary, top panel view of a pair of partition panels interconnected in an in-line or side-by-side relationship;
FIG. 24 b is a fragmentary, front elevational view of the in-line partition panels shown in FIG. 24 a;
FIG. 25 is an enlarged, fragmentary top plan view of adjacent horizontal stringers in the in-line partition panels shown in FIGS. 24 a and 24 b;
FIG. 26 is a vertical cross-sectional view of the adjacent horizontal stringers in the in-line panels of FIG. 25, shown before installation of a panel-to-panel clip;
FIG. 27 is a vertical cross-sectional view of the in-line horizontal stringers shown in FIG. 27, with a panel-to-panel clip shown partially installed therein;
FIG. 28 is a fragmentary, top plan view of the in-line horizontal stringers shown in FIG. 27, with the panel-to-panel connector clip shown fully installed;
FIG. 29 is a fragmentary, vertical cross-sectional view of the in-line horizontal stringers shown in FIG. 27, with the panel-to-panel connector clip shown fully installed;
FIG. 29 a is a perspective view of a panel-to-panel base clamp;
FIG. 30 is a perspective view of three of the partition panels, of which two are interconnected in-line, and one is interconnected at an angle or branched to the in-line panels;
FIG. 31 is a partially schematic, top plan view of the panels shown in FIG. 30, wherein the branched panel can be interconnect anywhere along the in-line panels;
FIG. 32 is a fragmentary, top-plan view of the panels shown in FIGS. 30 and 31, wherein portions thereof have been broken away to reveal internal construction;
FIG. 33 is a fragmentary, vertical cross-sectional view of the panels shown FIG. 32;
FIG. 34 is a perspective view of another integrated prefabricated partition system, which includes a partition panel system and a connection system embodying the present invention;
FIG. 35 is an exploded perspective view of a space frame of a base partition panel embodying the present invention;
FIG. 36 is a perspective view of the space frame shown in FIG. 35;
FIG. 37 is a plan view of the horizontally extending top frame member of the space frame shown in FIG. 36;
FIG. 38 is an end view of the top frame member shown in FIG. 37;
FIG. 39 is a fragmentary exploded perspective view of an end of the top frame member shown in FIG. 35, including the first in-line connector attached thereto;
FIG. 40 is a perspective view of a telescopeable bracket of a second in-line connector shown in FIG. 35;
FIG. 41 is a fragmentary perspective view of the other end of the top frame member shown in FIG. 35, including the second in-line connector attached thereto;
FIG. 42 is an enlarged, fragmentary perspective view of the space frame of the base partition panel shown in FIG. 36, including an optional cover support frame member;
FIG. 43 is a perspective view of a bracket for securing the optional cover support frame member to the base panel shown in FIG. 42;
FIG. 44 is a fragmentary perspective view of the optional cover support frame member shown in FIG. 42;
FIG. 45 is a fragmentary end elevational view of the base panel shown in FIG. 42;
FIG. 46 is an exploded perspective view of an off-module connector for interconnecting base partition panels in a T-shaped arrangement;
FIG. 47 is a perspective view of the off-module connector shown in FIG. 46;
FIG. 48 is a perspective view of the off-module connector attached to a first partition panel at an intermediate location between the vertical side edges of the first partition panel, the off-module connector being positioned to matingly receive and engage an in-line connector on a second partition panel for interconnecting the second partition panel to the first partition panel in an off-module position;
FIG. 49 is an end elevational view of the T-shaped arrangement of base panels shown in FIG. 48;
FIG. 50 is a perspective view of a space frame of the stacking partition panel shown in FIG. 34;
FIG. 51 is a partially exploded view of the stacking partition panel shown in FIG. 50;
FIG. 52 is an exploded perspective view of the stacking connector engaging the top frame member of a base partition panel, the stacking panel being removed to more clearly show the engagement of the stacking connector to the top frame member of the base partition panel;
FIG. 53 is a perspective view comparable to FIG. 52, but with the stacking connector engaging the top frame member of the base partition panel;
FIG. 53A is a fragmentary perspective view comparable to FIG. 53, but showing the bottom horizontal frame members of the top stacker frame and the top horizontal frame member of the bottom frame;
FIG. 54 is an exploded perspective view of the clamping members and clamping actuator for the stacking connector shown in FIG. 53;
FIG. 55 is a perspective view comparable to FIG. 54, but with the clamping members and clamping actuator being shown in an assembled position;
FIG. 56 is a front view of a clamping member shown in FIG. 55;
FIG. 57 is a side cross-sectional view taken along the plane LVII—LVII in FIG. 56;
FIG. 58 is a fragmentary elevational view of a stacked assembly including a base partition panel and a stacking partition panel;
FIG. 59 is a fragmentary end view of the stacked assembly shown in FIG. 58;
FIG. 60 is a perspective view of the cover support connector shown in FIG. 42;
FIG. 61 is a side cross-sectional view of the cover support connector shown in FIG. 61;
FIG. 62 is a perspective view of the interior side of a cover for covering a base panel;
FIG. 63 is a fragmentary perspective view of the top member of the marginal frame of the cover shown in FIG. 62;
FIG. 64 is an enlarged cross-sectional view taken along the plane LXIV—LXIV in FIG. 63;
FIG. 65 is a fragmentary perspective view of the bottom member of the marginal frame of the cover shown in FIG. 62;
FIG. 66 is an enlarged cross-sectional view taken along the plane LXVI—LXVI in FIG. 65;
FIG. 67 is an elevational cross-sectional view of a stacked subassembly including a stacking panel, a base panel, and covers attached thereto;
FIG. 68 is an enlarged view of the cover-to-panel connection at the top frame member of the base panel;
FIG. 69 is an enlarged view of the cover-to-panel connection at the intermediate rail of the base panel;
FIG. 70 is an enlarged view of the cover-to-panel connection at the bottom frame member of the base panel;
FIG. 71 is a perspective view showing a method of assembling a stacking panel to previously connected base partition panels and stacking partition panels in a wall construction;
FIG. 72 is a perspective view showing a method of disassembling a stacking partition panel from between other partition panels in a wall construction in a non-progressive manner;
FIG. 73 is a perspective view showing a method of assembling covers to a wall construction of base partition panels and stacking partition panels;
FIG. 74 is a perspective view showing a method of assembling the stacking partition panels and the base partition panels in a staggered/alternating arrangement;
FIG. 75 is a perspective view showing a method of assembling the covers to a wall construction of interconnected base and stacking partition panels with the covers being staggered on the wall construction;
FIG. 76 is a wall construction including staggered base and stacking partition panels, off-module connected partition panels, and covers;
FIGS. 77 and 78 are side and end views of a wall construction including a floor-engaging channel, a base panel, and a stacking panel, each including the in-line connectors shown in FIGS. 39-41;
FIGS. 79 and 80 are enlarged side and end views of lower parts of FIGS. 77 and 78, respectively;
FIG. 81 is an exploded perspective view of the leveling screws and the floor-engaging channel shown in FIGS. 79 and 80; and
FIGS. 82 and 83 are fragmentary side and end views showing the interconnection of the leveling screws on the base panel to the floor-engaging channel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate the invention as oriented in FIGS. 1 and 2. However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specifications are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
The reference numeral 1 (FIG. 1 ), generally designates a freestanding portable partition system that is designed for use in conjunction with open office spaces 2 , and other similar environments to form a plurality of work settings or work stations 3 . Partition system 1 includes a plurality of similar modular panels 4 (FIGS. 2 and 3 ), which are interconnected so as to define the desired work stations 3 . One such partition panel 4 is illustrated in FIGS. 2 and 3, and includes a base panel 5 , a stacker panel 6 , an expressway raceway 7 , and a transom 8 , which are stacked vertically on top of one another.
The base panel 5 (FIG. 3) includes a skeleton-like internal frame 9 having at least two vertical uprights 10 positioned adjacent opposite side edge thereof. A foot 11 extends downwardly from the bottom of frame 9 to abuttingly support base panel 5 on a floor surface. Two pairs of horizontal stringers 12 and 13 are attached to the outer faces of uprights 10 in a vertically spaced apart relationship to rigidly interconnect the same, and define therebetween two horizontal raceway cavities 14 and 15 , which open to the opposite side faces of frame 9 , and extend continuously between the opposite side edges thereof, such that when like base panels 5 are interconnected side-by-side, the open ends of adjacent raceway cavities 14 and 15 are aligned and communicate. Cover panels 16 enclose at least those portions of the frame side faces disposed between stringers 12 and 13 , and are detachably mounted thereon to provide ready access to the raceway cavities 14 and 15 , and permit lay-in wiring therealong.
Each of the illustrated vertical uprights 10 (FIGS. 9-11) includes a pair of arms 18 , which are attached to the outer faces thereof, and extend upwardly from upper ends thereof to define yoke-shaped receptacles 19 for receiving drop-in wiring therein. A third pair of horizontal stringers 20 are attached to the upper ends of arms 18 , and extend generally parallel and coplanar with associated stringers 12 and 13 . Each pair of stringers 12 , 13 , and 20 is spaced mutually laterally apart by the associated uprights 10 , so as to define a vertical raceway cavity 21 positioned intermediate the two horizontal raceway cavities 14 and 15 .
The illustrated base panel frame 9 (FIGS. 9-15) has an open, skeleton-like construction, that is preferably provided in a variety of different widths to accommodate various applications. However, in each illustrated embodiment of base panel 5 , the horizontal stringers 12 , 13 , and 20 are substantially longer than the vertical uprights 10 , such that each base panel 5 has a horizontally elongated elevational shape or datum. The base panel frame 9 illustrated in FIG. 3 includes a total of five vertical uprights 10 , each of which has a substantially identical, square tubular construction, comprising opposite side faces 28 (FIGS. 9-15) oriented toward the opposite sides of base panel 5 , and opposite end faces 29 oriented toward the opposite end edges of base panel 5 . The lower ends of vertical uprights 10 are attached to a C-shaped base channel 30 , which defines the panel foot 11 , and includes a top web 31 , and opposite side flanges 32 . A pair of threaded glides or feet 33 extend through the web 31 of base channel 30 into the bottom ends of outermost uprights 10 to provide vertical adjustability at the opposite sides or ends of base panel 5 . The illustrated arms 18 have a square tubular construction substantially identical to that of vertical uprights 10 , and include opposite side faces 34 , as well as opposite end faces 36 . The lower ends 37 of arms 18 are fixedly attached to the side faces 28 of vertical uprights 10 adjacent the upper ends thereof, and extend vertically upwardly therefrom a distance of approximately 2 to 4 inches in vertical alignment with the associated upright 10 , thereby defining the yoke-shaped receptacles 19 for drop-in wiring.
In the illustrated example of base panel frame 9 , each of the horizontal stringers 12 , 13 , and 20 has a square tubular construction that is substantially identical with that of vertical uprights 10 , and includes opposite faces 40 - 43 , and opposite ends 44 . Horizontal stringers 12 , 13 , and 20 have a length substantially identical with that of base panel 30 , and are arranged in a mutually parallel, vertically spaced apart relationship. In one working example of the present invention, stringers 13 are located approximately 4 inches above floor height, while stringers 12 are located approximately 30 inches above floor height. Horizontal stringers 12 and 13 have their inward faces 41 attached to the outer side faces 28 of vertical uprights 10 by means such as welding or the like. Stringers 20 have their bottom faces 43 rigidly attached to the upper ends 38 of arms 18 , and in one working embodiment of the present invention, the same are positioned approximately 40 inches above floor height. Each pair of stringers 12 , 13 , and 20 is mutually horizontally aligned on opposite sides of its associated vertical uprights 10 . The stringers 12 , 13 , and 20 on the opposite sides of vertical uprights 10 are horizontally coplanar, and facilitate the mounting of cover panels 16 and 17 thereon.
With reference to FIGS. 12-15, the illustrated horizontal stringers 12 , 13 , and 20 are slotted to permit like panels 4 to be interconnected and support various accessories thereon, as described in greater detail hereinafter. With reference to the upper stringers 20 , the rear or inward face 41 is full as shown in FIG. 12, while the opposite front face 40 (FIG. 14) includes a series of horizontal slots 50 , which extend continuously between opposite ends 44 thereof in a regular pattern. The bottom face 42 of horizontal stringers 12 includes an end slot 51 and a series of windows 52 , as shown in FIG. 13, while the opposite top face 43 has an end slot 53 and stacker apertures 54 , as shown in FIG. 15 . In the base panel frame 9 shown in FIGS. 10 and 11, a pair of clamp brackets 56 are mounted to the opposite ends of each lower stringer 13 and project downwardly therefrom. Each clamp bracket 56 includes a semi-circular notch 57 to is receive an associated panel-to-panel clamp 58 (FIGS. 24 b and 29 a ), as described below.
The illustrated cover panels 16 and 17 (FIGS. 4-8) for base panel 5 have a substantially similar construction, each with a rectangular front elevational shape that includes a top edge 60 , bottom edge 61 , opposite side edges 62 , and opposite faces 63 and 64 . The front faces 63 of cover panels 16 and 17 are preferably finished, so as to provide and aesthetically pleasing appearance, and may include upholstery, paint, wood veneer, as well as specialty surfaces, such as white board, chalk board, and the like. Each of the cover panels 16 and 17 has a width generally commensurated with that of its associated panel frame 9 , and a height generally commensurated with the vertical spacing between an associated pair of horizontal stringers 12 , 13 , and 20 . For example, in the base panel 5 illustrated in FIG. 3, cover panel 16 extends between medial portions of stringers 12 and 13 , while cover panel 17 extends between medial portions of stringers 12 and 20 . A full height cover 16 a is shown in FIG. 4, and extends between medial portions of stringers 13 and 20 to enclose the entire face of base panel frame 9 . L-shaped brackets 65 are attached to the interior faces 64 of cover panels 16 and 17 adjacent opposite corners thereof by fasteners 66 , or another suitable attachment system, such as adhesive, etc. Each of the brackets 65 has an outwardly extending flange 67 , which receives a spring-type mounting clip 68 thereon. As shown in FIG. 7, each clip 68 has a generally S-shaped side elevational configuration, comprising three parallel leg portions 69 - 71 . The outer leg 69 and center leg 70 form a U-shaped area that snaps onto the flange 67 of brackets 65 , as shown in FIGS. 5 and 6. The outer leg 71 includes a barb 73 that engages the window 52 on the associated stringers 12 , 13 , and 20 . Cover panels 16 and 17 are pushed inwardly onto frames 9 , so that clips 68 engage brackets 65 to detachably mount the cover panels in the fashion shown in FIG. 8 .
In use, the cover panels 16 , 17 , and 17 a are installed on an associated base frame 9 in the following fashion. The cover panels 16 , 17 , and 17 a are first selected from a group of different widths and heights to match the panel configuration desired. The selected cover panels 16 , 17 , and 17 a are then converged on to the opposite sides of the associated frame 19 , with clips 68 engaging the aligned stringers 12 , 13 , and 20 . Cover panels 16 , 17 , and 17 a are then urged inwardly against the associated panel frame 9 , so that the barb 73 on clips 68 engage aligned windows 52 in horizontal stringers 12 , 13 , and 20 to securely, yet removably, mount the same in place. Cover panels 16 , 17 , and 17 a are thereby positioned against or adjacent the outer faces 40 of horizontal stringers 12 , 13 , and 20 , thereby enclosing or completing the horizontal raceway cavities 14 and 15 , each of which has a vertically elongated shape when viewed in end elevation. The two horizontal raceway cavities 14 disposed between horizontal stringers 12 and 20 are located adjacent work surface height and define beltway raceway cavities. The two horizontal raceway cavities 15 disposed between horizontal stringers 12 and 13 are located adjacent to the panel base and define lower raceway cavities.
The illustrated stacker panel 6 (FIGS. 3 and 16) has a construction substantially similar to previously described base panel 5 , except that it does not have a foot 11 or an intermediate pair of stringers 13 . Stacker panel 6 also comes in a variety of different widths, as well as various heights, and mounts directly on top of an associated base panel 5 , as discussed in greater detail below.
The stacker panel 6 shown in FIG. 16 has a skeleton-like frame 80 comprising five vertical uprights 81 , which are spaced generally regularly along the width of stacker panel 6 . Each of the vertical uprights 81 is constructed from square tubing, substantially identical to that of base panel uprights 10 , and includes opposite pairs of faces 82 and 83 . Arms 84 (FIGS. 17 - 20 ), similar to base panel arms 18 , are attached to the opposite side faces 82 of each of the stacker panel uprights 81 , and extend upwardly from upper ends thereof to define Y-shaped receptacles 85 for drop-in wiring. A first pair of horizontal stringers 86 is attached to the upper ends of arms 84 , and a second pair of horizontal stringers 87 is attached to the side faces 82 of uprights 81 adjacent the lower ends thereof. Both pairs of stringers 86 and 87 are constructed from square tubing substantially similar to vertical uprights 81 , as well as the stringers 12 , 13 , and 20 associated with base panel frame 9 . Each of the stringers 86 and 87 associated with stacker panel frame 80 has a slotted configuration similar to the stringers 12 , 13 , and 20 of base panel frame 9 , and includes a series of horizontal slots 90 along the forward faces, end slots 91 and windows 92 on the top faces, and end slots 93 on the bottom faces.
The stacker panel 6 illustrated in FIG. 16 has a height substantially equal to the height of the lower panel 16 of the base panel 5 illustrated in FIG. 3, such that cover panel 16 can be mounted directly on the opposite sides of stacker panel frame 80 in the fashion described above with respect to base panel 5 . The interior spaces formed between stacker frame uprights 81 and their associated stringers 86 and 87 define horizontal raceway cavities 96 and 97 , which open toward the opposite faces of stacker panel 6 . Horizontal raceway cavities 96 and 97 that are substantially similar to the horizontal raceway cavities 14 and 15 associated with base panel 5 , and include open ends, which are aligned and communicate with adjacent like stacker panels to route utilities therebetween. Stacker panel 6 also has a vertical raceway cavity 98 (FIG. 17) formed in-between the two horizontal raceway cavities 96 and 97 .
As best illustrated in FIGS. 17-23, the lower stringers 87 on stacker panel frame 80 include a plurality of vertically extending threaded sleeves 104 positioned regularly along stringers 87 , which facilitate mounting stacker panel 6 on an associated base panel 5 . The lower ends of sleeves 104 extend downwardly from the lower surfaces of stringers 87 , and form pilots that are closely received and retained in the apertures 54 in the upper surfaces of stringers 12 on base panel 5 . Threaded fasteners 105 are inserted upwardly through the apertures 54 in base panel stringers 20 , and into the sleeves 104 of stacker panel 6 to securely interconnect the same.
In operation, the height of any given partition panel 4 can be easily varied by selecting the appropriate number and size of base panels 5 and stacker panels 6 . In the partition panel 4 illustrated in FIG. 3, a single stacker panel 6 is mounted on top of base panel 5 in the following manner. With all cover panels 16 , 17 , etc. removed, the selected stacker panel frame 80 is placed on top of the associated base panel frame 9 , so that the lower stringers 87 of stacker panel frame 80 rest directly on top of the upper stringers 12 on base panel frame 9 . The lower ends of sleeves 104 are inserted into apertures 54 on stringers 12 to squarely orient stacker panel frame 80 on top of base panel frame 9 . Fasteners 105 are then inserted through the apertures 54 in the upper stringer 12 of base panel frame 9 , and engaged in sleeves 104 to securely connect stacker panel frame 80 on top of base panel frame 9 . Cover panels 16 , 17 , etc. are then positioned over the outer faces of both frames 9 and 80 .
With reference to FIGS. 24 a - 29 a , adjacent partition panels 4 are interconnected in an in-line relationship or side-by-side in the following manner. Panel-to-panel clips 110 are provided, each having a plate-like construction with an upturned tab 111 at one end and a Z-shaped tab 112 at the opposite end. A threaded boss 113 is positioned at a medial portion of the clip 110 and is aligned with a mating aperture in which a threaded fastener 114 is received. In the in-line example illustrated in FIGS. 24 a - 29 a , when like base panel frames 9 are positioned end-to-end, the associated stringers 12 , 13 , and 20 are aligned with the opposite ends abutting one another. Any stacker panel frames 80 are similarly positioned end-to-end and aligned. With reference to the illustrated base panel 5 , the panel-to-panel clips 110 are used to interconnect the opposite ends of each adjacent pair of horizontal stringers 12 and 20 in the following manner. As shown in FIG. 27, the Z-shaped tab 112 of clip 110 is first inserted into the lower window 55 in one of the adjacent stringers, such as the illustrated stringer 12 . The head portion 115 of fastener 114 is positioned between the top and bottom faces 42 and 43 of the adjacent stringers 12 . The upturned tab 111 of clip 110 is then inserted into the lower window 55 of the opposite stringer 12 , and fastener 114 is then tightened, which may be accomplished by inserting a tool (not shown) through the windows 51 in the top faces 42 of stringers 12 . After all fasteners 114 have been tightened, the opposite tabs 111 and 112 on clips 110 positively interconnect the opposite ends of the associated stringers 12 . When a pair of base panels 5 are positioned in-line, preferably the ends of each of stringers 12 and 20 are thusly interconnected, thereby requiring four clips 110 .
In the example shown in FIG. 24 b , a panel-to-panel clamp 58 is used to interconnect the adjacent ends of the lower stringers 13 . As best shown in FIG. 29 a , panel-to-panel clamp 58 includes a pair of U-shaped bracket halves 117 , each having a pair of apertures 118 through which fasteners 119 are received. As shown in FIG. 24 b , the two clamp halves 117 are positioned on opposite sides of brackets 56 , with fasteners 119 passing through notches 57 . When fasteners 119 are tightened the opposite halves 117 of bracket 58 capture the four adjacent brackets 56 therein to securely interconnect the lower stringers 13 end-to-end.
With reference to FIGS. 30-33, partition panels 4 can also be interconnected in a branched or angular configuration in the following fashion. Branching clips 120 are provided and have a generally plate-shaped construction, which includes a upturned tab 121 at one end and a horizontally oriented hook 122 at the opposite end. A threaded boss 123 is mounted on a lower portion of branching clip 120 , and is aligned with a mating aperture in which a threaded fastener 124 is received. Branching clip 120 has a L-shaped center portion 125 , which extends along the end 44 of an associated one of the stringers, such as the illustrated stringer 12 .
In use, the partition panel 4 can be interconnected to a like partition panel 4 in an angular orientation at locations anywhere along the length of the in-line panels. For instance, in the example illustrated in FIGS. 30 and 31, three panels 4 are shown interconnected in an in-line orientation in the fashion described herein above. A single panel 4 is shown attached at a 90 degree angle to the three in-line panels at a position intermediate the opposite side edges of the center panel 4 . It is to be understood that the branched panel 4 can be attached anywhere along the length of the three in-line panels, which greatly facilitates space planning.
A branched panel 4 is mounted in the following manner. A pair of branching clips 120 are selected, and hook ends 122 are inserted into the adjacent slots 50 in stringers 12 , 13 , and 20 at the location at which the branched panel 4 is to be located. The heads 126 of fasteners 124 are positioned in the hollow interiors of stringers 12 . The tab ends 121 of clips 120 are shifted into the lower windows 55 in stringers 12 , and fasteners 124 are then tighten to securely interconnect the branched panel 4 .
ADDITIONAL EMBODIMENTS
A wall construction 150 (FIG. 34) includes a plurality of lower/base partition panels 151 and upper/stacking partition panels 152 interconnectable in an infinite number of different in-line, stacked, and off-module arrangements, including combinations thereof. More specifically, the panels 151 and 152 are interconnectable frame-to-frame with a connection system including mating in-line connectors 153 and 154 (FIGS. 39 - 41 ), off-module connectors 155 (FIGS. 46 - 48 ), and stacking connectors 156 (FIGS. 52 and 53 ). The panels 151 and 152 are reconfigurable to meet constantly changing office needs, including the ability to construct walls with “T” intersections located intermediate the vertical side edges of panels, and the ability to construct walls having different heights and/or non-uniform heights. (For example, compare FIGS. 34 and 71 - 75 .)
Base partition panel 151 (FIGS. 35 and 36) includes a base panel space frame 160 having a substantially rectangular side elevational configuration. The space frame 160 includes three vertically oriented structural tubes 161 - 163 which are interconnected in a laterally spaced apart relationship by four horizontally oriented structural tubes 164 - 167 and also by a pair of intermediate side frame members 168 and 169 . Notably, more or less vertical and horizontal structural tubes can be used if desired. In the illustrated example, center vertical tube 162 and horizontal tubes 164 - 167 have a square cross section, while end vertical tubes 161 and 163 have a rectangular cross section, the elongated dimension of the rectangle being oriented in a parallel is plane defined by the vertical tubes of the base partition panel 151 . Also, the intermediate side frame members 168 and 169 have a C-shaped cross section, with the legs of the C-shape facing inwardly and engaging the sides of the vertical tubes 161 - 163 and frame members 168 and 169 . The tubes 161 - 167 and side frame members 168 and 169 are welded together to provide a rigid space frame 160 for receiving and interconnecting with other space frames as discussed below. The vertical tubes 161 - 163 extend substantially from the top to the bottom of base space frame 160 , and the horizontal tubes and side frame members 164 - 169 extend substantially the width of space frame 160 and align with frame members in adjacently positioned panels.
A top frame member 171 (FIG. 35) is welded to the top of space frame 160 . Top frame member 171 (FIGS. 37 and 38) has a W-shaped cross section, including a U-shaped center frame section comprising center flange 172 and vertical side flanges 173 and 174 . A pair of inverted L-shaped side sections extend from side flanges 173 and 174 , respectively, including top flanges 175 and 176 and outermost side flanges 177 and 178 , respectively. The top frame member 171 is welded to top horizontal tubes 164 and 165 (see FIG. 68) to form a rigid matrix. A row of apertures 179 (FIG. 39) are formed at the juncture of flanges 175 and 177 , and at the juncture of flanges 176 and 178 . The apertures 179 extend partially onto side flanges 177 and 178 so that they are accessible horizontally from a location beside the partition panel. As described hereinafter, the apertures 179 are accessible through a gap between covers attached to the space frames for receiving off-module connectors 155 , and also for receiving an Allan wrench to operate the actuator 293 of stacking connectors 156 .
A pattern 183 of second apertures is also formed at intervals of about every few inches along the top frame member 171 , such as every 12 inches. Aperture pattern 183 includes a horizontal slot 184 formed in center flange 172 , a front-side middle aperture 185 formed at the juncture of flanges 173 and 175 , and an opposing rear-side middle aperture 186 is formed at the juncture of flanges 174 and 176 . Longitudinally adjacent right and left apertures 187 and 188 are formed in flange 173 on both sides of middle aperture 185 , and longitudinally adjacent right and left apertures 189 and 190 are formed in flange 174 on both sides of middle apertures 186 . Pattern 183 further includes notches 191 and 192 formed in selected ones of the apertures 179 , the selected ones being the apertures 179 ′ spaced two apertures from the apertures 179 ″ centered in aperture pattern 183 (FIG. 52 ). The notches 191 and 192 are located in top flanges 175 and 176 , respectively, at the corners of the apertures 179 ′ located farthest apart. The center flange 172 and side flanges 173 and 174 are cutaway at the opposing ends 172 ′ and 172 ″ (FIG. 37) of top frame member 171 to provide room for in-line connectors 153 and 154 .
In-line connector 153 (FIG. 39) includes a W-shaped reinforcement bracket or platform 195 having a center flange 196 , vertical intermediate flanges 197 and 198 extending from center flange 196 , horizontal flanges 199 and 200 extending from intermediate flanges 197 and 198 , and upright vertical side flanges 201 and 202 extending from horizontal flanges 199 and 200 . Upright flanges 201 and 202 are spaced apart to fit mateably between and against outermost side flanges 177 and 178 at the end of top frame member 171 so that they can be welded to frame member 171 . A stiffening flange 203 is formed on the outer end of bracket 195 on center flange 196 . A cinch-plate receiving aperture 204 is formed at the juncture of center flange 196 and vertical intermediate flange 197 at a location spaced from stiffening flange 203 , and a second cinch-plate receiving aperture 205 is formed at the juncture of center flange 196 and vertical intermediate flange 198 at a second location spaced from stiffening flange 203 . A U-shaped basket 206 is welded to the underside of center flange 196 . The basket 206 includes spaced apart first and second legs 207 and 208 attached to center flange 196 on opposing longitudinal sides of apertures 204 and 205 . A cinch plate 210 is located within basket 206 . Cinch plate 210 includes a body 211 including a threaded hole 211 ′, and opposing wings 212 that extend at an angle outwardly from body 211 . The wings 212 are spaced apart and configured to extend through the cinch-plate receiving apertures 204 and 205 . A screw 214 is configured to extend through a hole 215 in center flange 196 and threadably into cinch plate 210 . Basket 206 retains cinch plate 210 on bracket 195 and maintains the alignment of the cinch plate 210 with apertures 204 and 205 as screw 214 is turned. By rotating screw 214 , cinch plate 210 is drawn against center flange 196 , thereby causing wings 213 to extend through apertures 204 and 205 . Slots 217 and 218 are formed in the ends of horizontal flanges 199 and 200 , respectively, for receiving a trim piece, a trim piece retainer or the like.
In-line connector 154 includes a telescopeably movable bracket 220 (FIG. 40 ). Telescopeable bracket 220 is elongated and U-shaped, and includes a center flange 221 and side flanges 222 and 223 which are configured to mateably rest on and straddle center flange 196 of connector bracket 195 (FIG. 41 ). Two cinch-plate receiving apertures 224 and 225 (FIG. 40) are formed along the juncture of flanges 221 and 222 , and also two cinch-plate receiving apertures 226 and 227 are formed along the juncture of flanges 221 and 223 . A slot 228 extends from an end 229 of bracket 220 , and extends past apertures 224 - 227 . As shown in FIG. 41, bracket 220 is configured to mateably slidably rest on center flange 196 of reinforcement bracket 195 of off-module connectors 155 in an extended position, with the apertures 225 and 227 aligned with apertures 204 and 205 . Alternatively, telescopeable bracket 220 is movable to a retracted position wherein apertures 224 and 226 are aligned with apertures 204 and 205 on reinforcement bracket 195 . In the extended position, the apertures 224 and 226 are extended to a position alignable with cinch-plate receiving apertures 204 and 205 on an adjacent and aligned base panel 151 so that the adjacent base panels can be rigidly interconnected in an in-line, frame-to-frame arrangement. Notably, it is contemplated that termination elements for connecting a panel 151 to an architectural wall or the like and for filling the space therebetween will be constructed with one end having a laterally extending bracket simulating extendable bracket 220 for connection to an end panel 151 , and having a second end configured for connection to the architectural wall. The laterally extending bracket can be fixed, removable (e.g., bolted), or extendable, and the termination element can include conventional telescoping or field-cuttable elements.
As discussed below, covers are attached to the sides of base space frame 160 . In some situations, it may be desirable to support the covers with an intermediate brace 230 (FIG. 42 ). This also allows the covers to be halved in size, such that one cover can be supported between the top frame member 171 and the intermediate brace 230 , and a second cover between the intermediate brace 230 and the intermediate side frame member 168 and 169 . The intermediate brace 230 includes a sheet metal bracket 231 welded to vertical structural tubes 161 (and 162 and 163 ) at a predetermined height. Bracket 231 (FIG. 43) includes an L-shaped body having a vertical flange 232 and horizontally disposed top flanges 233 , the top flanges 233 defining a notch 233 ′ therebetween for mateably engaging the vertical structural tube 161 (or tubes 162 and 163 ). The top flanges 233 include holes 234 . The lower edge of vertical flange 232 includes teeth 235 . Intermediate brace 230 also includes a structural beam 236 (FIG. 44) that is generally C-shaped. Brace 236 includes a top flange 237 having holes 237 ′, a vertical flange 238 having a row of apertures 238 ′ and paired holes 239 periodically spaced across its length, and a lower flange 240 defining a space configured to mateably receive teeth 235 on bracket 231 . Structural beam 236 is attached to bracket 231 by positioning teeth 235 in the space defined by lower flange 240 (FIG. 45 ), and by tipping beam 236 onto bracket 231 so that holes 237 ′ in brace 236 align with holes 234 in bracket 231 . Screws 240 ′ are extended through the aligned holes 234 a and 237 to secure the beam 236 to base space frame 160 . It is noted that the apertures 238 ′ are generally identical to apertures 179 of top frame member 171 in shape and function.
The off-module connectors 155 (FIG. 46) include a pair of configured plates 245 and 246 slidably interconnected by a pair of rivets or headed bolts 247 and 248 . Lower plate 245 is generally Z-shaped and includes an upper flange 249 having hooks 250 , a middle flange 251 that extends generally perpendicular to upper flange 249 , and a lower flange 252 the extends from middle flange 251 parallel upper flange 249 . A pair of holes 253 are formed in middle flange 251 , along with a window 254 located between the holes 253 . A pair of apertures 255 and 256 are formed in lower flange 252 . A slot 257 extends from the free edge 258 of lower flange 252 between apertures 255 and 256 . An angled tab 259 extends from free edge 258 along a side edge of lower flange 252 . Upper plate 246 is also generally Z-shaped so that it matingly slidingly engages lower plate 245 . Upper plate 246 includes an upper flange 260 having hooks 261 , a middle flange 262 that extends generally perpendicular to upper flange 260 , and a lower flange 263 the extends from middle flange 262 parallel upper flange 260 . Hooks 261 face in a direction opposite to hooks 250 . A pair of aligned slots 264 are formed in middle flange 262 , along with a window 265 located between the holes 264 . Rivets 247 and 248 extend loosely through holes 253 and slots 264 so that upper plate 246 can slide on lower plate 245 with rivets 247 and 248 sliding within slots 264 on middle flange 262 of upper plate 246 . A pair of apertures 266 and 267 are formed in lower flange 263 . A slot 268 extends from the free edge 269 of lower flange 263 between apertures 266 and 267 . An angled tab 270 extends from free edge 269 along a side edge of lower flange 263 .
Plates 245 and 246 (FIG. 47, shown in the expanded position) are movable to a collapsed first position where hooks 250 and 261 are positioned to form a minimum dimension so that the hooks can be slid into selected ones of apertures 179 in top frame member 171 . The plates 245 and 246 are also movable to an expanded second position (shown in FIG. 47) where the hooks 250 and 261 are spread apart to securely engage the apertures 179 (see FIG. 48 ). A detent or friction-generating spring can be added to hold the plates 245 and 246 in the selected position to facilitate assembly of a wall construction if desired. When in the second position, the apertures 255 and 266 , and also the apertures 256 and 267 are aligned so that they can be engaged by the wings 212 on cinch plate 210 of an in-line connector 152 (see FIG. 39 ). Also, the angled tabs 259 and 270 (FIG. 47) are adapted to engage the recesses defined beside the center flange 172 of top frame member 171 to limit the expanding/collapsing movement of plates 210 245 and 246 and to help center off-module bracket 154 on an off-module connected panel. Thus, the off-module connectors 155 are adapted to be installed and secured selectively along the base space frame 160 . Once installed, a base panel 151 can be positioned in an off-module arrangement (see FIGS. 48 and 76) so that an in-line connector 153 on the base panel can be attached to the off-module connectors 155 with its cinch plate 210 engaging apertures 255 and 266 , and 256 and 267 . The off-module connectors 155 connect the frame of the off-module space frame 160 directly to the base panel 151 , such that the interconnection is particularly rigid.
Stacking panel 152 (FIGS. 50 and 51) includes a space frame 280 substantially structurally identical to base space frame 160 except as noted below. In particular, the stacking space frame 280 includes a plurality of vertically oriented structural tubes 281 - 283 which are interconnected in a laterally spaced apart relationship by a plurality of horizontally oriented structural tubes 284 - 287 and also by a pair of intermediate side frame members 288 and 289 . The vertical tubes 281 - 283 extend substantially from the top to the bottom of space frame 280 , and the horizontal tubes and side frame members 284 - 289 extend substantially the length of space frame 280 . A top frame member 290 is attached horizontally to the top of stacking space frame 280 , the top frame member 290 being similar to base top frame member 171 . A plurality of upright transom-supporting brackets 291 are optionally attached to the top of stacking panel 290 to support a transom thereon. Transom-supporting bracket 291 comprises a lower panel 291 ′ welded or bolted to top frame member 290 , and a pair of oppositely facing C-shaped channels 291 ″ configured to receive and retain elongated transom panels, such as windows or opaque sound absorbing panels not unlike covers 334 . A plurality of spaced apart stacking connectors 156 are attached to the bottom of stacking panel 152 at spaced apart positions corresponding to the spacing of aperture patterns 183 on top frame member 171 (FIGS. 35 - 37 ). This allows the stacking partition panel 152 to be selectively positioned on top frame member 171 in any of a variety of different/longitudinally spaced positions, several of which are staggered, as described below. (For example, see FIGS. 74 and 76.)
Stacking connectors 156 (FIG. 52, 53 , and 53 A) each include a carrier bracket 292 and a pair of opposing clamping members or gripping members 294 and 294 ′ slidably mounted on the carrier bracket 292 . An actuator 293 operably engages the clamping members 294 and 294 ′ to forcibly spread apart the clamping members into interlocking engagement with the selected aperture pattern 183 . Notably, the present invention is contemplated to include other stacking connector designs, such as a stacking connectors constructed so that its clamping members are drawn together into engagement with outwardly facing apertures in a top frame member of a space frame.
In the present embodiment, the carrier bracket 292 (FIG. 52) is a stamped sheet metal part that includes a center flange 295 and a pair of inverted U-shaped locating flanges 296 and 297 extending from the longitudinal sides of center flange 295 . An aperture 298 is formed in center flange 295 , and tabs 299 and 300 extend upwardly from center flange 295 for slidably engaging and aligning clamping members 294 and 294 ′ on carrier bracket 292 . Locating flanges 296 and 297 each include notches 302 and tabs 303 at their front and rear ends for mateably engaging notches 191 and 192 in apertures 179 ′ of aperture pattern 183 . When carrier bracket 292 is positioned on top frame member 171 , bracket center flange 295 is juxtaposed above center flange 172 of top frame member 171 , and bracket tabs 303 interlockingly engage the apertures 179 ′ in top frame member 171 . Thus, stacking connector 156 can be selectively engaged with top frame member 171 at any of a plurality of different staggered/interconnected positions (e.g., every 12 inches along the length of top frame member 171 ). This allows the vertical side edges 304 of stacking partition panel space frame 280 to be offset from the vertical side edges 305 of base partition panel space frame 160 , in order to form a stronger stacked arrangement of panels (see FIG. 74 ).
Clamping members 294 and 294 ′ are substantially mirror images of each other, except as described below. Clamping member 294 (FIG. 54) includes a body 307 having an outer surface 308 and an inner surface 309 . A pair of lower fingers 310 and 311 extend from the outer surface 308 at the bottom thereof, and a centered upper finger 312 extends from the top of outer surface 308 . Fingers 310 - 312 are configured to matingly engage apertures 187 , 189 and 185 , respectively, (FIG. 52) on one side of aperture pattern 183 in top frame member 171 . The bottom surface of clamping member 294 is configured to slidably rest on and engage the center flange 172 of carrier bracket 292 . An oblong aperture 316 having ends defining a pair of spaced apart hole-like surfaces 317 and 318 extends horizontally through clamping member 294 from front to rear. A hole 315 extends horizontally through clamping member 294 ′ and aligns with the hole-like surface 317 in clamping member 294 ′.
Actuator 293 includes an elongated nut 320 configured to matingly non-rotatingly engage hole 315 . The nut 320 includes a washer-like flange 321 on its inner end configured to matingly engage a depression 322 on the inner surface of clamping member 294 ′. Actuator 293 further includes a first shaft 323 configured to threadably engage nut 320 for rotation therein. Shaft 323 also includes a portion that extends through the hole-like surface 317 in clamping member 294 . A second shaft 325 operably engages the second hole-like surface 318 in clamping member 294 . Intermeshing gears 327 and 328 are formed on the adjacent ends of shafts 323 and 325 , respectively. Hex-shaped recesses 329 and 330 are formed in the rear end of shaft 323 and on the front end of shaft 325 , respectively. The hex-shaped recesses 329 and 330 are engageable with an Allan wrench through apertures 193 ″ (FIG. 52) to actuate actuator 293 . Specifically, when one shaft is rotated by the Allan wrench, the other shaft is simultaneously oppositely rotated by the intermeshing gears 327 and 328 . This causes the shaft 323 to gradually rotate out of nut 320 , thus forcing the clamping members 294 and 294 ′ apart. This causes fingers 310 - 312 to interlockingly engage apertures 185 - 190 of aperture pattern 183 .
Cover retainers 355 (FIGS. 60 and 61) are provided for securing covers 334 (FIG. 62) to base and stacking space frames 160 and 280 . Retainers 355 include threaded shafts 356 for engaging holes 355 ′ in horizontal structural frame members 168 , 169 , 171 , and 230 (FIGS. 42 and 67 ). Retainers 355 (FIGS. 60 and 61) further include tapered heads 357 and washers 358 defining a recess/groove 359 therebetween.
Covers 334 (FIG. 62) are configured for attachment to cover retainers 355 . Covers 334 include a sound-absorbing composite panel 335 aesthetically covered with upholstery or the like and having a selected size. A marginal frame 336 is attached to the edges of panel 335 , including a top marginal frame section 337 (FIG. 63) and a bottom marginal frame section 338 . The top marginal frame member 337 includes an inner flange 339 , a top flange 340 , and a front flange 341 . A plurality of attachment apertures 342 and 343 are formed along top marginal frame member 337 , apertures 342 being formed in inner flange 339 , and apertures 343 being formed in top flange 340 . A tab can be extended from inner flange 339 to outer flange 341 , if desired, to assist in supporting front flange 341 relative to inner flange 339 and to stiffen top marginal frame member 337 . Bottom marginal frame member 338 (FIG. 65) also includes an inner flange 345 , a bottom flange 346 , and an outer flange 347 , and further includes apertures 348 formed in inner flange 345 at spaced intervals along the length of bottom marginal frame member 338 . A pair of angled tabs 350 are formed inwardly from inner flange 345 to inner flange 347 . Angled tabs 350 assist in supporting panel 335 within the bottom marginal frame member 338 .
Covers 334 (FIGS. 67-70) are releasably secured to base space frame 160 and stacking space frame 280 by positioning the apertures 342 of top marginal frame members 337 on the heads of several cover retainers 355 . The material forming the aperture 342 is then slid downwardly into the recess 359 of cover retainer 355 (FIG. 60) so that the top marginal frame member 337 of the cover 334 is interlocked thereon (see FIGS. 67 - 70 ). The cover 334 is then rotated downwardly along direction “A” until the bottom marginal frame member 338 is located adjacent base space frame 160 (or 280 ). The bottom marginal cover frame section 338 is secured to base space frame 160 by patches of hook and loop material 360 (FIG. 67 ). A light shield 361 extends below bottom marginal frame section 338 to prevent unacceptable see-through along the gap 338 ′ between upper and lower covers 334 and 334 ′ on base space frame 160 , and also in the gap between adjacent covers on stacking panel 152 and base panel 151 . It is contemplated that the hook-and-loop material could be replaced with other retention systems, such as a tab and aperture system, snap-in carrot-like fasteners, adhesive, or other fasteners.
The base partition panels 151 and stacking partition panels 152 can be interconnected in a myriad of different arrangements by the in-line connectors 153 and 154 , the off-module connectors 155 , and the stacking connectors 156 . FIG. 71 discloses a typical in-line wall construction 350 wherein the base partition panels 151 and stacking partition panels 152 are interconnected in an in-line arrangement. In wall construction 350 , the vertical side edges 351 of the panels 151 and 152 are aligned. Recalling that the stacking connectors 156 are accessible through apertures 179 in the top frame member 171 of base partition panel 151 , and that the in-line connectors 153 and 154 are accessible from the top of stacking partition panel 152 , it will be noted that a particular stacking partition panel 152 ′ positioned in the middle of wall construction 350 can be removed in a non-progressive disassembly by disengaging the stacking connectors 156 and the in-line connectors 153 and 154 (FIG. 72 ). Thereafter, the base partition panel 151 ′ can also be removed by disengaging its in-line connectors 153 and 154 . Thus, panels 151 ′ and 152 ′ can be replaced. Alternatively, the panels 151 ′ and 152 ′ can be “permanently” removed and a walkway through the panels can be created. Covers 334 (FIG. 73) are attached to the various partition panels 151 and 152 to aesthetically cover same. Notably, top and bottom covers 334 are spaced apart to form the gap 338 ′ therebetween (FIG. 67 ). This allows access to apertures 179 along horizontal frame members 168 , 169 , 171 , and 230 of space frames 160 and 280 , such that stacking panels 152 can be removed without removing covers 334 from the stacking panels 152 , thus reducing disassembly and reassembly time and also reducing the risk of damage to loose covers.
The stacking partition panels 152 can also be attached to base partition panels 151 in a staggered arrangement (FIG. 74) to form a wall construction 363 , wherein the vertical side edges of the panels 151 and 152 are misaligned. The misalignment is accomplished by engaging stacking connectors 156 with selected aperture patterns 183 to position the stacking panel 152 offset from the base panel 151 . Advantageously, this increases the strength of the wall construction 363 since there is no continuous vertical side edge formed by the staggered arrangement. In regard to wall construction 363 (see FIG. 34 ), which discloses a wall construction that is three sections high and staggered, the third section being a second stacking panel, a transom section, or an expressway section. Notably, the wall construction can be partial height or full height and/or connected to a structural ceiling or a drop ceiling.
The covers can also be attached to the partition panels 151 and 152 in a staggered arrangement, as illustrated by cover 365 in FIG. 75 to form a wall construction 364 , or as illustrated by covers 334 ′ in FIG. 34 . This allows covers of non-uniform length and spacing to be used on the wall constructions. For example, this can be advantageous for aesthetics since the vertical lines in a wall construction can be broken up. Also, the staggered arrangement of covers allows increased flexibility for design, since new combinations of colors and arrangement patterns can be achieved. Still further, the staggered arrangement offers advantages in terms of positioning covers to form gaps at strategic locations, such as for positioning of cabling and wiring modular outlets, or for routing cabling and wiring therethrough, such as to an off-module connected wall section.
The wall construction 366 (FIG. 76) includes in-line connected base partition panels 151 and stacking partition panels 152 interconnected in a staggered arrangement, and further includes off-module base partition panel 151 ″ and an off-module stacking partition panel 152 ″ connected in an off-module T-shaped arrangement. Covers 334 are shown attached to the in-line connected wall section to show their relationship to the off-module connected wall section. Notably, the panels can be used to construct wall constructions having T, H, Z, or X-shaped plan configurations. Also, the panels can be constructed using stacking panels attached above other stacking panels. The above description of non-progressive removal is possible even where both ends of a panel are connected with an off-module connection. (For example, see off-module constructed wall section in FIG. 34.)
A number of different floor-engaging constructions are contemplated. For example, a floor-engaging and kickway-forming member can be attached to the bottom of base panel space frame 160 , such as the downwardly facing U-shaped channel shown in FIGS. 4 and 11 for forming the bottom kickway of base panel 151 . Alternatively, relatively short leveling screws or leveling feet can be welded to the bottom of vertical tubes 161 - 163 as desired without incorporating a kickway-forming bracket thereon. Still another alternative is to attach an upwardly facing U-shaped channel to the floor, with the U-shaped channel being configured to mateably receive the bottom of the base panels 151 (or the leveling feet attached to base panels 151 ).
A floor-securement system 375 (FIGS. 77 and 78) has been developed that incorporates a modified version of the panel-mounted in-line connectors 153 and 154 to facilitate constructing a wall construction 376 . Floor-securement system 375 includes a floor-engaging channel 380 having ends with mating in-line connectors 381 and 382 thereon that are not unlike in-line 10 connectors 153 and 154 . The channel 380 further includes apertured side walls 383 and 384 configured to receive off-module connectors 155 (FIG. 47 ). Floor-engaging channel 380 (FIG. 79) is constructed to securely engage base space frame 160 , and for this purpose includes slidably movable interlock brackets 426 for releasably engaging leveling members 386 . By retaining channel 380 to leveling members 386 , the channels 380 can be shipped pre-assembled to panels 151 or shipped separate therefrom. Also, the panels 151 , when assembled together, can be positively secured to the channels 380 , and the channels 380 can be positively secured to the building floor, which provides a very positive construction having advantages such as resistance to damage from earthquakes and other catastrophic events.
Floor-engaging channel 380 (FIG. 81) has a W-shaped cross section reminiscent of top frame member 171 . Channel 380 is formed by a center flange 390 , vertical intermediate side flanges 391 and 392 , floor-engaging horizontal flanges 393 and 394 , and vertical outer side flanges 383 and 384 . Floor-engaging flanges 393 and 394 can be secured to a floor by adhesive, nails, and other ways known in the trade. Flanges 390 - 392 form a U-shaped section configured to slidably receive the extendable brackets 220 shown in FIG. 40 and previously described. A nut 397 is welded under a hole 398 near the end of center flange 390 , and a screw 399 with washer/enlarged head 400 thereon is configured to threadably engage nut 397 through hole 398 . When screw 399 is loosened, bracket 220 is movable between an extended position and a retracted position. Screw 399 can then be screwed into nut 397 to clampingly retain bracket 220 in the selected position. When extended, bracket 220 can be mateably engaged by an end of an aligned and adjacent floor-engaging channel 382 with the corresponding screw 399 on the mating channel being positioned in slot 228 of bracket 200 . In this aligned and adjacent position, the corresponding screw 399 in the adjacent channel can be screwed into its nut to clampingly retain the bracket 220 , thus securing the adjacent channels 380 in an aligned and interconnected position. Notably, it is contemplated that the nut 397 will be welded to center flange 390 , although a cinch plate could be used, like that in-line connectors 153 and 154 , if desired.
Side flanges 383 and 384 each include a row of apertures 402 defining discrete attachment points positioned generally along the lowermost edge of side flanges 383 and 384 (FIG. 81 ). The apertures 402 generally correspond to the apertures 179 on top rail member 171 (FIGS. 37 and 48 ). Apertures 402 (FIG. 81) are engageable by off-module bracket 155 (FIG. 47) by inverting the off-module bracket 155 so that teeth 250 and 261 can be engaged with apertures 402 (FIG. 81) with off-module bracket 155 engaged with selected apertures 402 , the apertured flanges 252 and 262 (FIG. 46) extend laterally and are located above the floor, where they are engageable by an in-line connector 381 on an off-module connected channel 380 .
A kickway cover 403 (FIG. 83) is configured for use with channel 380 . Kickway cover 403 includes a resilient clip-like end 404 configured to clip attach to the top of side flange 383 (or 384 ). Kickway cover 403 further includes a horizontally extending lower leg 405 that spaces a vertical extending upper leg 406 from side flange 383 . Upper leg 406 is biased inwardly by clip-like end 404 (FIG. 83) so that when a panel cover 334 (FIG. 80) is attached to the base panel 151 , upper leg 406 presses against the panel cover 334 . The inner surface of upper leg 406 includes hook-like features 407 and 408 for receiving tabs on an end cover for the kickway on an end panel. Notably, like panel covers 334 , kickway covers 403 can bridge or span between adjacent base panels 151 .
Floor-engaging channel 380 (FIG. 82) includes a plurality of support brackets 420 positioned under center flange 390 at locations generally corresponding to the predetermined locations of leveling members 386 on base panel 151 . Support brackets 420 each include a platform 421 supported by floor-engaging feet 422 and 423 . Platform 421 includes a leveler receiving hole 425 defined by a frustoconically-shaped annular flange 424 . A U-shaped interlock bracket 426 is slidably positioned on center flange 390 above platform 421 . Interlock bracket 426 includes a longitudinally extending slot 427 (FIG. 81) and a keyhole slot 428 having an enlarged end 429 and a smaller end 430 . Interlock bracket 426 includes a retention tab 431 engageable with an aperture 432 in center flange 390 and in aligned aperture 433 in platform 421 . A bolt 434 is extended through slot 427 threadably into a threaded hole 435 (FIG. 82) in platform 421 . Bolt 434 cooperates with tab 431 to secure interlock bracket 426 to channel 380 . Interlock bracket 426 is movable in direction “A” (FIG. 81) to a first position wherein the enlarged end 429 of interlock bracket 426 is aligned with frustoconically-shaped hole 425 on platform 421 . Interlock bracket 426 is further slidably movable to a second position wherein the smaller end 430 of keyhole slot 428 is aligned with frustoconically-shaped hole 425 .
Leveling member 386 (FIG. 81) includes a vertically disposed rod 440 welded to a vertical frame member such as frame member 161 on panel 151 . A threaded nut 442 is welded to rod 440 , and a threaded rod section 443 is operably engaged with nut 442 and extended therebelow. The lower end 444 of threaded rod 443 is tapered to mateably engage frustoconically-shaped hole 425 , and has a diameter permitting it to slide through the enlarged end 429 of keyhole slot 428 . The lower end 44 includes a narrowed section 445 with back surface 446 that is interlockingly engageable with the smaller end 430 of keyhole slot 428 .
Initially, the interlock bracket 426 is moved to the first position so that the enlarged end 429 of keyhole slot 428 aligns with frustoconically-shaped hole 425 . A panel 151 is then placed in floor-engaging channel 380 with the tapered lower end 444 of leveler 386 mateably engaging tapered hole 425 of platform 421 . Interlock bracket 426 is then slid to the second position so that the smaller end 430 of keyhole slot 428 is aligned with tapered hole 425 . In this position, interlock bracket 426 engages the back surface 446 on tapered lowered end 444 to interlockingly retain the base panel 151 to channel 386 .
This arrangement has several advantages. The arrangement permits pre-assembly of channel 386 to base panels 151 , which can be advantageous for shipping, but also optionally allows the channels 386 to be shipped separately and assembled on-site. Further, whether it is pre-assembled or assembled on-site, the channel can be interlocked to securely retain panels 151 to channel 386 . This has significant value, not only to facilitate installation but also for resisting damage from earthquakes, for meeting “earthquake codes,” and for resisting damage from other catastrophic events.
Thus, a wall construction is illustrated including base partition panels and stacking partition panels, interconnectable with in-line connectors, off-module connectors, and stacking connectors. The wall construction is connectable and reconfigurable in a variety of in-line and off-module connected arrangements, and in a variety of vertically aligned and staggered/misaligned arrangements.
In the foregoing description, it will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed herein. Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise.
|
A partition system for subdividing a building space includes a spine partition having a horizontal frame member defining a first horizontal row of apertures for supporting a furniture unit, and a floor channel configured to stably engage a floor surface and supporting the partition. The floor channel defines a second horizontal row of apertures corresponding to the first horizontal row of apertures for supporting the furniture unit. A fin partition has an end positioned adjacent a front of the spine partition at an off-module position located between vertical side edges of the spine panel, with a top and bottom of the end attached to selected apertures in the first and second rows of apertures. A method related to the above is also claimed.
| 4
|
CROSS-REFERENCE TO RELATED APPLICATION
The present application is a Continuation-In-Part (C.I.P.) application of patent application Ser. No. 10/145,789 filed on May 16, 2002, now abandoned.
FIELD OF THE INVENTION
The present invention relates to the general field of construction components and is particularly concerned with a length adjustable composite stud.
BACKGROUND OF THE INVENTION
Construction beams are used extensively in the construction field especially for the construction of partition walls. Indeed, partition walls typically include a framework made out of a plurality of vertical beams referred to as studs assembled together with generally horizontal beams often referred to as plates. Sheets of wall board are typically secured to both sides of the framework to produce wall surfaces.
Typically, the studs are fastened to the plates by driving nails through the outwardly facing surfaces of the plates and into the top and bottom end of each stud. This method, often referred to as “toe nailing”, allows for quick and easy fastening of a stud to top and bottom plates.
Wood studs have traditionally been favored for use in construction studs for their structural characteristics as well as the ease with which they can be assembled to plates using the “toe nailing” approach. However, with time, disadvantages associated with wood studs are becoming more apparent, particularly in view of the unavailability of suitable wood materials caused the depletion of forest resources. Also, wood stud are prone to cracking and warping. They are further susceptible to termite infestation, rotting and mildew.
Accordingly, metal frames are becoming increasingly popular. Conventional metal frames are typically made out of extruded strips. When properly constructed and at appropriate thickness, conventional frames are relatively rigid, strong and structurally stable. In addition, metal frame are generally impervious to weather conditions. In facts, metal frames alleviate most of the disadvantages associated with wood studs.
One of the major disadvantages associated with the use of metal studs is the extra effort required for connecting the metal studs to the plates as compared with the relative ease with which the “toe nailing” approach can be performed with wood studs. Hence, it would be highly desirable to combine the advantages associated with metal studs with the ease of assembly afforded by the use of wood studs.
The attractiveness of combining characteristics from metal and wood studs has been recognized in the prior art. For example, U.S. Pat. No. 5,452,556 naming Jimmy R. TAYLOR as inventor and issued Sep. 26, 1995 discloses a fabricated combination of an elongated metal channel and at least two short lengths or end portions of a wooden beam. The combination forms a standard length stud having a metal central portion and exposed wooden portions.
Although somewhat useful, the structure disclosed in U.S. Pat. No. 5,452,556 nevertheless suffers from at least one major drawback. Indeed, during the construction of wall skeletal frameworks, there exists a plurality of situations wherein it is desirable to adjust the length of the wood studs. For example, the wall being erected may extend between floor and/or ceiling that are either warped or angled relative to each other. The structure disclosed in U.S. Pat. No. 5,452,556 does not allow for easy, quick and ergonomic adjustment of the length of the composite metal-wood studs. Accordingly, there exists a need for an improved length adjustable composite stud.
SUMMARY OF THE INVENTION
It is an object of the present invention to provided an improved construction stud.
Advantages of the present invention include that the proposed composite wood-metal stud combines the advantages associated with metal studs such as improved structural stability and decreased susceptibility to termite infestation, mildew and the like with the advantages associated with conventional wood studs such as the ability to join the studs to structural plates through the use of the conventional “toe nailing” approach.
The proposed length adjustable composite stud allows for customized adjustments of the length of the stud. The length of the proposed composite stud can be adjusted using a set of simple and ergonomic steps without requiring special tooling or manual dexterity.
Furthermore, the proposed length adjustable composite stud is designed so as to be manufacturable using conventional forms of manufacturing so as to provide a stud that is economical, long lasting and relatively trouble free in operation.
In accordance with an embodiment of the present invention, there is provided a length adjustable composite stud comprising: a generally elongated frame member, the frame member defining a frame longitudinal axis, a frame first longitudinal end and a generally opposed frame second longitudinal end; the frame member defining a generally open base channel, the base channel having a longitudinal channel opening; a core component, the core component defining a core longitudinal axis, a core first longitudinal end and an opposed core second longitudinal end; the core component being at least partially insertable in the base channel with the core longitudinal axis in a generally parallel relationship relative to the frame longitudinal axis to form the composite stud therewith, the core component being axially and slidably movable relative to the frame member when at least partially inserted within the base channel; transversal movement limiting means positioned between the frame member and the core component for preventing relative movement between the core component and the frame member in a direction other then the frame longitudinal axis when the core component is at least partially inserted within the base channel; longitudinal movement limiting means positioned between the frame member and the core component for releasably retaining the core component within the base channel in a core first position wherein the core first longitudinal end is generally in register with the frame first longitudinal end, the longitudinal movement limiting means selectively allowing longitudinal movement of the core component in a core first direction towards a core second position upon a moving force being applied on the core component, wherein when the core component is in the core second position, the core first longitudinal end protrudes from the frame first longitudinal end so as to adjust a length of the composite stud, while preventing the core component to be axially moved relative to the base frame from the core first position in a core second direction oriented opposite the core first direction.
In accordance with one embodiment of the invention, the longitudinal movement limiting means only allows longitudinal movement of the core component in the core first direction upon the moving force reaching a predetermined value.
In accordance with one embodiment of the invention, the core component is in the core first position and wherein the longitudinal movement limiting means includes a retaining strip, the retaining strip being secured to both the core component and the frame member for releasably preventing longitudinal movement therebetween, the retaining strip extending generally circumferentially relative to the core component and the frame member.
Conveniently, the retaining strip is releasably secured to the core component and the frame member for selectively allowing longitudinal movement therebetween.
According to an aspect of the present invention, there is provided a length adjustable composite stud comprising:
a generally elongated frame member, the frame member defining a frame longitudinal axis, a frame first longitudinal end and a generally opposed frame second longitudinal end; the frame member defining a generally open base channel, the base channel having a longitudinal channel opening; a core component, the core component defining a core longitudinal axis, a core first longitudinal end and an opposed core second longitudinal end; the core component being configured and sized for allowing the core component to be at least partially inserted in the base channel with the core longitudinal axis in a generally parallel relationship relative to the frame longitudinal axis; transversal movement limiting means positioned between the frame member and the core component for preventing relative movement between the core component and the frame member in a direction other then the frame longitudinal axis; longitudinal movement limiting means positioned between the frame member and the core component for releasably retaining the core component within the base channel in a core first position wherein the core first longitudinal end is generally in register with the frame first longitudinal end, the longitudinal movement limiting means selectively allowing longitudinal movement of the core component in a core first direction towards a core second position upon a moving force being applied on the core component, wherein when the core component is in the core second position, the core first longitudinal end protrudes from the frame first longitudinal end.
Typically, the longitudinal movement limiting means only allows longitudinal movement of the core component in the core first direction upon the moving force reaching a predetermined value.
Typically, the core component is in the core first position and the longitudinal movement limiting means includes a retaining strip, the retaining strip being secured to both the core component and the frame member for releasably preventing longitudinal movement therebetween.
Typically, the retaining strip is releasably secured to the core component and the frame member for selectively allowing longitudinal movement therebetween, and the retaining strip is provided with indicia marked thereon that includes instructions relating to a method for using the length adjustable composite stud.
Preferably, the retaining strip is made out of a tearable material, the tearable material being tearable upon the moving force reaching a predetermined value.
Preferably, the core component defines a core first cross-sectional area and a core second cross-sectional area, the core first cross-sectional area being insertable into the base channel and the core second cross-sectional area protruding through the channel opening when the core first cross-sectional area is inserted into the base channel; the retaining strip being adhesively secured to the core second cross-sectional area and to the base member.
Preferably, the frame member has a generally U-shaped cross-sectional configuration defining a frame base wall and a pair of frame side walls; the frame base wall defining a base wall inner surface, a base wall outer surface and a pair of opposed base wall main peripheral edges; each of the frame side walls defining a corresponding side wall inner surface, a side wall outer surface, a side wall first main edge and a generally opposed side wall second main edge; each of the side wall first main edges being attached to a corresponding one of the base wall main peripheral edges; the frame side walls extending from the frame base wall so that the side wall inner surfaces are in a generally facing relationship relative to each other, the frame base wall and the frame side walls together forming the base channel; each of the frame side walls including a retaining flange extending inwardly from the side wall inner surface adjacent the side wall second main edge;
the core component having a generally rectangular cross-sectional configuration defining a core first main wall, a core second main wall, a core first auxiliary wall and a core second auxiliary wall; the core component being configured and sized so as to be insertable into the base channel with the core first main wall positioned generally adjacent the base wall inner surface and the core first and second auxiliary walls positioned generally adjacent a corresponding one of the side wall inner surface; the core first auxiliary wall being provided with a first retaining slot extending longitudinally at least partially therealong, the first retaining slot being configured and sized for receiving at least a section of one of the retaining flanges when the core component is inserted into the base channel; the core second auxiliary wall being provided with a second retaining slot extending longitudinally at least partially therealong, the second retaining slot being configured and sized for receiving at least a section of the other one of the retaining flanges when the core component is inserted into the base channel; the first and second retaining slots extending generally transversally towards each other in a generally transversal slot plane, the slot plane extending generally between the core first cross-sectional area and the core second cross-sectional area, the retaining strip being adhesively secured to the core second cross-sectional area and to at least one of the frame side walls.
Preferably, the transversal movement limiting means includes at least one retaining flange extending from the frame member, the retaining flange being configured and sized for abutting against a section of the core component when the latter is inserted in the base channel.
Alternatively, the longitudinal movement limiting means includes an abutment tab extending inwardly into the base channel, the abutment tab being configured, sized and positioned so as to abuttingly contact the core second longitudinal end when the core component is in the core first position.
Preferably, the frame member has a generally U-shaped cross-sectional configuration defining a frame base wall and a pair of frame side walls; the frame base wall defining a base wall inner surface, a base wall outer surface and a pair of opposed base wall main peripheral edges; each of the frame side walls defining a corresponding side wall inner surface, a side wall outer surface, a side wall first main edge and a generally opposed side wall second main edge; each of the side wall first main edges being attached to a corresponding one of the base wall main peripheral edges; the frame side walls extending from the frame base wall so that the side wall inner surfaces are in a generally facing relationship relative to each other, the frame base wall and the frame side walls together forming the base channel; each of the frame side walls including a retaining flange extending inwardly from the side wall inner surface adjacent the side wall second main edge;
the core component has a generally rectangular cross-sectional configuration defining a core first main wall, a core second main wall, a core first auxiliary wall and a core second auxiliary wall; the core component being configured and sized so as to be insertable into the base channel with the core first main wall positioned generally adjacent the base wall inner surface and the core first and second auxiliary walls positioned generally adjacent a corresponding one of the side wall inner surface; the core first auxiliary wall being provided with a first retaining slot extending longitudinally at least partially therealong, the first retaining slot being configured and sized for receiving at least a section of one of the retaining flanges when the core component is inserted into the base channel; the core second auxiliary wall being provided with a second retaining slot extending longitudinally at least partially therealong, the second retaining slot being configured and sized for receiving at least a section of the other one of the retaining flanges when the core component is inserted into the base channel; the first and second retaining slots extending generally transversally towards each other in a generally transversal slot plane, the slot plane generally between the core first cross-sectional area and the core second cross-sectional area; the abutment tab extending inwardly from the frame base wall.
Alternatively, the longitudinal movement limiting means includes a retaining aperture extending through the frame member and a retaining component, the retaining aperture being configured, sized and positioned so that the retaining component is insertable into both the retaining aperture and the core component when the core component is in the core first position.
Preferably, the retaining component has a generally elongated and pointed configuration.
Typically, the longitudinal movement limiting means only allows longitudinal movement of the core component in the core first direction, the longitudinal movement limiting means preventing the core component from moving in the core second direction.
Alternatively, the longitudinal movement limiting means includes a gripping tab extending from the frame member into the base channel, the gripping tab being configured and sized so as to allow movement of the core component in the core first direction while preventing movement of the core component in the core second direction by gripping into the core component.
Preferably, the gripping tab defines a tab contacting segment for contacting the core component and a tab spacing segment extending between the frame member and the tab contacting segment for inwardly spacing the tab contacting segment from the frame member, the tab contacting segment defining a tab gripping end for gripping into the core component when the core component is moved in the core second direction.
Preferably, the gripping tab is movable between a tab first position wherein the tab gripping end is spaced by a first tab-to-frame distance from the frame member and a tab second position wherein the tab gripping end is spaced by a second tab-to-frame distance from the frame member, the first tab-to-frame distance being greater then the second tab-to-frame distance.
Preferably, the composite stud also includes a tab biasing means positioned between the frame member and the gripping tab for biasing the gripping tab towards the tab first position.
Preferably, the tab biasing means includes the gripping tab being made out of a resiliently deformable material.
Alternatively, the longitudinal movement limiting means includes a stud projection connected to the core component and an elongate guide channel located in the frame member, the stud projection being slidably mounted in the guide channel.
Preferably, the elongate guide channel is configured, sized and positioned to abuttingly engage the stud projection when the core component moves between the core first position and the core second position.
Other objects and advantages of the present invention will become apparent from a careful reading of the detailed description provided herein, with appropriate reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be disclosed, by way of example, in reference to the following drawings in which like reference characters indicate like elements throughout.
FIG. 1 , in a perspective view, illustrates a length adjustable composite stud in accordance with an embodiment of the present invention, the length adjustable composite stud being shown used with similar length adjustable composite studs and with horizontal plate components attached thereto for forming a skeleton frame structure part of a conventional partition wall;
FIG. 2 , in a partial perspective view, illustrates a length adjustable composite stud in accordance with a first embodiment of the present invention, the length adjustable composite stud being shown with its core component in a first position;
FIG. 3 , in a partial perspective view, illustrates the length adjustable composite stud shown in FIG. 2 with its core component being moved towards a core second position;
FIG. 4 , in a partial perspective view taken along line 4 of FIG. 1 , illustrates the length adjustable composite stud shown in FIGS. 2 and 3 with its core component in a core second position and a with a section of a plate component attached thereto;
FIG. 5 , in a partial perspective view, illustrates a length adjustable composite stud in accordance with a second embodiment of the present invention, the length adjustable composite stud being shown with its core component in a core second position;
FIG. 6 , in a partial perspective view, illustrates a length adjustable composite stud in accordance with an embodiment of the present invention, the length adjustable composite stud being shown with its core component in a core second position wherein it protrudes from the end section of the frame member;
FIG. 7 , in a partial elevational view taken along line 7 — 7 of FIG. 6 with sections taken out, illustrates a length adjustable composite stud in accordance with an embodiment of the present invention, with its core component being moved in a core first direction towards a core second position wherein it protrudes from the end section of the frame member;
FIG. 8 , in a view similar to FIG. 7 , illustrates a length adjustable composite stud in accordance with an embodiment of the present invention, the length adjustable composite stud being shown with its core component being moved in a core second direction;
FIG. 8 a, in an enlarged partial elevational view taken along line 8 a of FIG. 8 with sections taken out, illustrates details of a gripping tab of the embodiment of FIG. 8 ;
FIG. 9 , in a partial elevational view taken along line 9 of FIG. 1 with sections taken out, illustrates a length adjustable composite stud in accordance with yet another embodiment of the present invention, the length adjustable composite stud being shown with its core component in a core first position wherein it is generally in register with the frame member;
FIG. 10 , in a partial elevational view with sections taken out, illustrates a length adjustable composite stud in accordance with an embodiment of the present invention with its core component being moved towards a core second position wherein it protrudes from the frame member;
FIG. 11 , in a partial elevational view with sections taken out, illustrates a length adjustable composite stud in accordance with an embodiment of the present invention with its core component fixed in a core second position wherein it protrudes from the frame member;
FIG. 12 , in a partial elevational view with sections taken out, illustrates a length adjustable composite stud in accordance with yet another embodiment of the present invention, the length adjustable composite stud being shown with its core component in a core first position wherein it is generally in register with the frame member; and
FIG. 13 , in a partial elevational view with sections taken out, illustrates a length adjustable composite stud with its core component being moved towards a core second position wherein it protrudes from the frame member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the annexed drawings the preferred embodiments of the present invention will be herein described for indicative purpose and by no means as of limitation.
Referring to FIG. 1 , there is shown a length adjustable composite stud 10 in accordance with an embodiment of the present invention. The length adjustable composite stud 10 is shown being used with other composite studs 10 ′ for supporting conventional horizontal end plates 12 . The length adjustable composite studs 10 , 10 ′ and the end plates 12 are shown assembled together for forming the skeleton frame of a conventional wall.
The length adjustable composite stud 10 includes a generally elongated frame member 14 . The frame member 14 defines a frame longitudinal axis 16 , a frame first longitudinal end 18 and a generally opposed frame second longitudinal end 20 . The frame member 14 defines a generally open base channel 22 having a channel opening 24 .
Typically, the frame member 14 has a generally U-shaped cross-sectional configuration defining a frame base wall 26 and a pair of frame side walls 28 . As shown more specifically in FIGS. 2 through 6 , the frame base wall 26 defines a base wall inner surface 30 , a base wall outer surface 32 and a pair of opposed base wall main peripheral edges.
Each of the frame side walls 28 defines a corresponding side wall inner surface 34 , a side wall outer surface 36 , a side wall first main edge 38 and a generally opposed side wall second main edge 40 . Each of the sidewall first main edges 38 is attached to a corresponding one of the base wall main peripheral edges.
The frame side walls 28 extend from the frame base wall 26 so that the side wall inner surfaces 34 are in a generally facing relationship relative to each other. The frame base wall 26 and the frame side walls 28 thus together form the base channel 22 . It should be understood that although the frame member 14 is shown throughout the figures as having a generally U-shaped cross-sectional configuration, the frame member 14 could have other cross-sectional configurations without departing from the scope of the present invention.
The composite stud 10 also includes a core component 42 . The core component 42 defines a core longitudinal axis 44 , a core first longitudinal end 46 and an opposed core second longitudinal end 48 . The core component 42 is configured and sized for allowing the core component 42 to be at least partially inserted in the base channel 22 with the core longitudinal axis 44 in a generally parallel relationship relative to the frame longitudinal axis 16 .
The composite stud 10 further includes a transversal movement limiting means positioned between the frame member 14 and the core component 42 for preventing relative movement between the core component 42 and the frame member 14 in a direction other than the frame longitudinal axis 16 . Typically, the transversal movement limiting means includes one and preferably two keepers or retaining flanges 50 extending from the frame member 14 . Typically, each retaining flange 50 extends inwardly from one of the side wall inner surfaces 34 adjacent a side wall second main edge 40 . The retaining flanges 50 are configured and sized for abutting against a section of the core component 42 when the latter is inserted in the base channel 22 .
Typically, each core component 42 has a generally rectangular cross-sectional configuration defining a core first main wall 52 , a core second main wall 54 , a core first auxiliary wall 56 and a core second auxiliary wall 58 . The core component 42 is typically configured and sized so as to be insertable into the base channel 22 with the core first main wall 52 positioned generally adjacent the base wall inner surface 30 and the core first and second auxiliary walls 56 , 58 positioned generally adjacent a corresponding one of the side wall inner surfaces 34 .
The core first and second auxiliary walls 56 , 58 are typically provided respectively with a first and a second retaining slot 60 , 62 extending longitudinally at least partially therealong. The first and second retaining slots 60 , 62 are configured and sized for receiving at least a section of a corresponding one of the retaining flanges 50 when the core component 42 is inserted into the base channel 22 .
It should be understood that although component 42 is shown as having a generally rectangular cross-sectional configuration, the core component 42 could have other configurations without departing from the scope of the present invention. Also, although the transversal movement limiting means is shown as including retaining flanges 50 , it should be understood that the transversal movement retaining means could include other components also without departing from the scope of the present invention.
The composite stud 10 still further includes longitudinal movement limiting means for releasably retaining the core component 42 within the base channel 22 in a core first position illustrated in FIG. 2 wherein the core first longitudinal end 46 is generally in register with the channel first longitudinal end 18 . The longitudinal movement limiting means is positioned between the frame member 14 and the core component 42 .
The core component 42 defines an anchoring surface 64 about the core first longitudinal end 46 . The core anchoring surface 64 typically has a generally flat configuration.
The frame member 14 defines a frame first longitudinal edge 66 about the frame first longitudinal end 18 . When the core component 42 is in the core first position, the core anchoring surface 64 and the frame first peripheral edge 66 typically extend in a generally common geometrical plane.
The longitudinal movement limiting means selectively allows longitudinal movement of the core component 42 in a core first direction indicated by arrow 68 towards a core second position upon a moving force 70 being applied on the core component 42 . The core component 42 moving in the core first direction eventually reaches a core second position illustrated in FIGS. 3 through 6 , wherein the core first longitudinal end 46 protrudes from the frame first longitudinal end 18 . In other words, in the core second position, the core anchoring surface 64 is spaced outwardly in the direction of the core longitudinal axis 44 relative to the frame first peripheral edge 66 .
In at least one embodiment of the invention, the longitudinal movement limiting means only allows longitudinal movement of the core component 42 in the core first direction 68 upon the moving force 70 reaching a predetermined value. In an embodiment of the invention shown in FIGS. 2 through 4 , the longitudinal movement limiting means includes a retaining strip 72 . The retaining strip 72 is secured to both the core component 42 and the frame member 14 for releasably preventing longitudinal movement therebetween.
In one embodiment of the invention, the retaining strip 72 is releasably secured to the core component 42 and/or to the frame member 14 so as to selectively allow longitudinal movement therebetween when the retaining strip 72 is removed from either or both the core component 42 and the frame member 14 . For example, the retaining strip 72 could be releasable adhesively secured to the core component 42 and/or the frame member 14 .
In another embodiment of the invention, the retaining strip 72 is made out of a tearable material. Typically, the tearable material is capable of being torn upon the moving force 70 reaching a predetermined value, or simply by using a knife or the like prior to applying the force 70 .
Typically, the core component 42 defines a core first cross-sectional area 74 and a core second cross-sectional area 76 . The core first cross-sectional area 74 is insertable into the base channel 22 while the core second cross-sectional area 76 protrudes from the channel opening 24 when the core first cross-sectional area 74 is inserted into the base channel 22 .
Typically, the first and second retaining slots 60 , 62 extend generally transversely towards each other in a generally transversal slot plane. The slot plane, in turn, extends generally between the core first and second cross-sectional areas 74 , 76 . The retaining strip 72 is typically adhesively secured to the core second cross-sectional area 76 and to the side wall outer surface 36 of at least one, and preferably both frame side walls 28 .
The embodiment shown in FIGS. 2 through 4 is typically sold or otherwise provided with the core component 42 positioned in the core first position such as illustrated in FIG. 2 . The core component 42 is prevented from longitudinal movement in the direction of the frame longitudinal axis 44 by the retaining strip 72 adhesively secured to both the frame member 14 and the core component 42 .
If the length of the length adjustable stud 10 needs to be adjusted, the intended user merely needs to exert a moving force 70 in the direction of the core first direction. Upon the moving force 70 reaching a predetermined value, the retaining strip 72 will be torn allowing relative movement between the core component 42 and the frame member 14 as illustrated in FIG. 3 .
Once the length of the length adjustable stud 10 has been adjusted, the core component 42 may be secured in the core second position using conventional fastening means such as a fastening nail 78 or the like inserted through both the frame member 14 and the core component 42 . The anchoring surface 64 can then be used for securing a plate 12 using an anchoring screw 80 or other suitable means.
The retaining strip 72 is typically made out of a self-adhesive strip of paper, polymeric resin or the like being tearable upon a predetermined tearing force being applied thereon. Optionally, the retaining strip 72 is provided with indicia 82 printed or otherwise marked thereon. The indicia 82 may include identifying information and/or instructions relating to a method for using the length adjustable composite stud 10 .
In another embodiment of the invention shown more specifically in FIG. 5 , the longitudinal movement limiting means includes an abutment tab 84 extending inwardly into the base channel 22 . The abutment tab 84 is configured, sized and positioned so as to abuttingly contact the core second longitudinal end 48 when the core component 42 is in the core first position.
Typically, the abutment tab 84 extends inwardly from the frame base wall 26 . Alternatively, the abutment tab 84 could extend from the side walls 28 , the retaining flanges 50 or any other suitable location. Typically, the abutment tab 84 has a generally half-disk shaped configuration. The abutment tab 84 could also have other configurations without departing from the scope of the present invention. Typically, the abutment tab 84 is punched-in during the manufacturing process, hence creating a corresponding adjacent cut-out 86 .
In use, the core component 42 is allowed to be pushed towards the core second position by a moving force 70 exerted in the core first direction 68 . Upon the core component 42 reaching the core second position, the core component 42 is again secured to the frame member 14 using suitable securing means such as the securing nail 78 . An end plate 12 can then be secured to the anchoring surface 64 using an anchoring screw 80 .
Referring now more specifically to FIGS. 6 through 8 , there is shown a length adjustable composite stud 10 in accordance with yet another embodiment of the invention. The composite stud 10 includes at least one gripping tab 88 extending from the frame member 14 into the base channel 22 .
Preferably, the longitudinal movement limiting means includes a set of gripping tabs 88 longitudinally aligned in spaced apart relationship relative to each other and extending from both the frame side walls 28 . Each gripping tab 88 is configured and sized so as to allow movement of the core component 42 in the core first direction 68 while preventing movement of the core component 42 in the opposite core second direction 68 ′.
Typically, as illustrated in FIG. 8 a, each gripping tab 88 defines a tab contacting segment 90 for contacting the core component 42 and a tab spacing segment 92 extending between the frame member 14 and the tab contacting segment 90 for inwardly spacing the tab contacting segment 90 from the frame member 14 . The tab contacting segment 90 defines a tab gripping end 94 for gripping into the core component 42 when the core component 42 is moved in the core second direction 68 ′.
As illustrated more specifically in FIG. 7 , each gripping tab 88 is typically movable between a tab first position shown in the lower end of FIG. 7 wherein the tab gripping end 94 is spaced by a first tab-to-frame distance 96 from the frame member 14 and a tab second position shown in the upper end of FIG. 7 wherein the tab gripping end 94 is spaced by a second tab-to-frame distance 98 from the frame member 14 . The first tab-to-frame distance 96 being greater then the second tab-to-frame distance 98 .
Typically, the composite stud 10 also includes a tab biasing means positioned between the frame member 14 and the gripping tab 88 for biasing the gripping tab 88 towards the tab first position. Typically, the tab biasing means includes the gripping tab 88 being made out of a generally resilient deformable material such as a suitable metallic alloy.
Typically, each gripping tab 88 is punched out of one and preferably both the frame side walls 28 . Also, typically, each gripping tab 88 has a generally triangular shaped configuration with the tip pointed towards the closest frame longitudinal end 16 , 18 . It should however be understood that the gripping tabs 88 could have other configurations without departing from the scope of the present invention.
In use, the longitudinal movement limiting means shown in FIGS. 6 to 8 only allows longitudinal movement of the core component 42 in the core first direction 68 . The longitudinal movement limiting means prevents the core component 42 from moving in a core second direction 68 ′ oriented opposite the core first direction 68 .
As shown in FIG. 7 , the core component 42 is allowed to slide in the core first direction 68 while abuttingly contacting the gripping tabs 88 . The latter are biased towards the tab second position by the core second first and second auxiliary surfaces 56 , 58 . When the core component 42 is moved back in from the core second position, the tab gripping end 94 penetrates into the first and second core auxiliary surfaces 56 , 58 for preventing further movement of the core component 42 in the core second direction 68 ′.
Referring now more specifically to FIGS. 9 through 11 , there is shown the steps of using a length adjustable composite stud 10 in accordance with still another embodiment of the present invention. In the embodiment shown in FIGS. 9 through 11 , the longitudinal movement limiting means includes a retaining aperture 100 extending through the frame member 14 and a generally elongated retaining component 102 . The retaining aperture 100 is configured, sized and positioned so that the retaining component 102 is insertable into both the retaining aperture 100 and the core component 42 when the core component 42 is in the core first position.
Once the end plate 12 is secured against the anchoring surface 64 of the core component 42 via the anchoring screw 80 , the retaining component 102 is removed from the core component 42 and the retaining aperture 100 , as shown by arrow 104 of FIG. 9 . Then the length of the composite stud 10 is adjusted by longitudinally sliding the core component 42 along with the end plate 12 outwardly from the frame member 14 in a core second position, as shown by arrow 106 of FIG. 10 . Finally, once in proper length, the retaining component 102 is re-inserted through the retaining aperture 100 into the core component 42 to secure the latter to the frame member 14 , as shown by arrow 108 of FIG. 11 .
In another embodiment of the invention shown more specifically in FIGS. 12 and 13 , the longitudinal movement limiting means includes an elongate guide channel 110 and a stud projection 112 . The elongate guide channel 110 is located in the frame base wall 26 , although the guide channel 110 may be located in the side walls 28 . The stud projection 112 is secured in the core main first main wall 56 and is slidably mounted in the engage the guide channel 110 . The guide channel 110 is configured so that the stud projection 112 abuttingly engages the ends of the guide channel 110 when the core component is moved between the core first position and the core second position, as shown in FIGS. 12 and 13 respectively. Once located in the second core position, the fastener 78 can be used to secure the core component 42 to the frame member 14 .
Typically, the retaining component 102 has a generally elongated and pointed configuration. By way of example, the retaining component can take the form of a conventional retaining screw or the like.
Although the present length adjustable composite stud has been described with a certain degree of particularity, it is to be understood that the disclosure has been made by way of example only and that the present invention is not limited to the features of the embodiments described and illustrated herein, but includes all variations and modifications within the scope and spirit of the invention as hereinafter claimed.
|
A length adjustable composite stud combining the advantages associated with metal studs with the advantages associated with conventional wood studs. The composite stud also allows for customized adjustments of its length using a set of simple and ergonomic steps. The composite stud includes a generally elongated frame member defining a generally open base channel. The composite stud also includes a core component configured and sized for allowing insertion thereof in the base channel. A transversal movement limiting component prevents relative movement between the core component and the frame member in a direction other then that of the frame longitudinal axis. A longitudinal movement limiting structure releasably retains the core component within the base channel in a core first position wherein a core longitudinal end is generally in register with a frame longitudinal end. The longitudinal movement limiting structure selectively allows longitudinal movement of the core component.
| 4
|
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to Turkish Patent Application Serial No. 2010/01999 filed on Mar. 16, 2010, the entirety of which is hereby incorporated herein by reference for all purposes.
FIELD OF THE INVENTION
The present invention relates to mechanisms transforming rotational movement to different movement characteristics.
BACKGROUND
There is a plurality of applications where rotational movement has to be converted to another different movement type. For instance, in machines like eccentric press, crank-connection rod mechanisms are used converting rotational movement to linear movement. In more details, such presses operate with the kinetic power of a big circular metal (flywheel) accelerated by an electric motor. Accordingly, the flywheel rotates continuously by means of the rotation movement it takes from the motor, however, the flywheel spindle does not rotate. When it is desired to be pressed on the piece, the flywheel spindle begins rotating by means of a clutch control like pedal. The rotation movement on the flywheel spindle is transferred to the eccentric spindle functioning as a crank by decreasing of the rotation number by means of gears. The function of the eccentric spindle is to transform circular movement to linear movement. Thus, linear movement (it is called press movement distance or stroke in the related technical field) equal to the eccentricity of the crank spindle is realized to the movable ram connected to the rod arm which is connected to the press crank spindle.
This embodiment which is widespread in the technical field has some disadvantages. For instance, in general the movement distance (it is called course in the related technical field) in these presses is constant. On the other hand, in press processes, the movement distance of the manufactured piece required with respect to the drawing depth changes. Therefore, in crank-connection rod and link-drive mechanism presses, the press is designed with respect to the maximum movement distance required and it realizes said course in every tour thereof even if most of the time this is not required. This means making the upper mould and the ram body do unnecessary movements and lose energy.
In the presses (course adjusted presses) where the movement distance can be adjusted, this adjustment process is a process which takes a long time and which requires labor. The amount of the eccentricity is determined using a piece called wedge for adjustment whose thickness increases along the length thereof, thus the press movement distance is increased or decreased. For this process, naturally the press should be stopped for a while and thus the production in the line where the press is placed should be stopped for a while. This process which takes a long time to be completed leads to time and production loss in mass production lines. Moreover, in the presses with low tonnage and in C-type presses, automatic course adjustment can be realized.
Moreover, as known in the technical field, in order to obtain a functional movement characteristic, the displacement distance should be limited in maximum to the radius of the eccentric gear. Thus, for longer distances, eccentric gears with a bigger diameter should be manufactured. This situation limits the movement distance of the press to be produced, with the bench capacity used in thread forming; thus since a more advanced technology is required for processing bigger gears than a certain size, this increases costs seriously.
Another problem is that in these types of presses, particular movement characteristics can not be realized. For instance, in a press application, the press may have to move downwardly with a slow movement, it may have to accelerate after a certain point and it may have to stay for a certain time in press position to the piece. As a result, such a movement characteristics can not be realized by a standard crank-connection rod mechanism. Such an operation can be realized only by expensive systems like servo press in the present art.
As an advantageous and different solution, some press embodiments using a gear box similar to a planet gear system as drive transfer mechanism are disclosed. As known, planet gear system in general decreases revolution as a gear box, or it can be used for increasing torque or for decreasing torque. Accordingly, the concentricity of the ring gear, the planet carrier and the sun gear provides an important advantage in the fields requiring concentric power transfer. The planet gear systems which are the subject of these patents realize the transformation of rotational movement to linear movement, therefore they are used for a different purpose.
For instance, in the U.S. Pat. No. 3,158,057 where the drive system of a cinnamon cutter blade is explained, a main planet gear whereon a rod arm is hinged is moved along the inner surface of a main planet gear ring gear in a circular route and thus the rod arm moves downwardly-upwardly in a linear direction. In this embodiment, since the other planets and the sun gear are removed from the mechanism, the mechanism disclosed can not be used in processes with high tonnage where high response forces are formed. In practice, since all of the load will be applied to the hinge point on the main planet gear of the rod arm, the connection here can not endure the forces of hundreds and even thousands of tones. Anyhow since the mechanism in U.S. Pat. No. 3,158,057 is used for cinnamon cutting process, in such a process, high response forces do not exist, thus U.S. Pat. No. 3,158,057 does not comprise a solution in this direction.
In the U.S. Pat. No. 2,338,352, a press embodiment is disclosed which is suggested to endure high level of forces and which has a drive transfer mechanism similar to planet gear. Accordingly, an inner gear whereon the rod arm is hinged eccentrically realizes both rotational and orbital movement along the inner surface of a circular gear, thus the elliptical movement formed is transferred to the rod arm as a linear movement. However, in this patent, an effective solution which will distribute the force arriving to the main planet gear where the rod arm is hinged is not disclosed.
As a result, because of the abovementioned disadvantages, a novelty is required in the related technical field.
SUMMARY
The present invention is a novel movement transformation mechanism improved in order to eliminate above mentioned disadvantages and to bring new advantages to the relevant technical field.
An object of the subject matter invention is to provide a movement transformation mechanism which can transform rotational movement to different movement characteristics by means of simple adjustments to be realized thereon.
An object of the subject matter invention is to make the movement transformation mechanisms with gear boxes which are similar to planet gear group have more resistance to big forces.
Another object of the subject matter invention is to provide a movement transformation mechanism providing the easy changing of the movement distance and/or the hitting characteristics of the presses.
In order to realize all of the objects obtained from the above explanation and the below mentioned detailed explanation, the present invention relates to a movement transformation mechanism comprising a main planet gear; a planet carrier which rotates together with said main planet gear; a ring gear which is positioned at the continuation of said planet carrier and is independent of the planet carrier and which has at least an inner surface having a gear structure, and a main planet gear which is rotatably connected to the planet carrier and whose thread is in contact with the thread on the inner surface of the ring gear and whereon the rod arm is hinged. In said mechanism, the diameter of said ring gear is at least two times greater than the diameter of the main planet gear provided that the diameter ratio is always an integer. Moreover, in addition to the main planet gear, the subject matter mechanism comprises at least two support planet gears which are rotatably connected to the planet carrier and whose thread are in contact with the thread on the inner surface of the ring gear and between said main and support planet gears and it comprises at least one support gear group with a sun gear positioned so as to contact with these gears.
In a preferred embodiment of the present invention, the diameter of the ring gear is two times greater than the diameter of the main planet gear and the sun gear is not concentric with the ring gear.
In another preferred embodiment of the present invention, while the ring gear is held fixed, when the planet carrier is rotated, in order to provide linear movement of the hinge point, said hinge point is on the front surface of the main planet gear and it has a distance with the main planet gear center equal to the main planet gear radius.
In another preferred embodiment of the present invention, there are at least two additional support planet gears which are positioned so as not to contact with the gears in said support gear group, which are rotatably connected to the planet carrier and whose thread are in contact with the thread on the inner surface of the ring gear, and between said main and additional support planet gears, there is at least one additional support gear group with an additional sun gear which is positioned so as to contact with these gears.
In a preferred embodiment of the present invention, in order to change the position of the hinge point with respect to the orthogonal axis passing through the center of the ring gear, there is an adjustment mechanism which rotates the main planet gear in the own axis thereof by rotating the ring gear in the own axis thereof while the planet carrier is fixed.
In another preferred embodiment of the present invention, the ring gear of said adjustment mechanism comprises a geared external wall and accordingly a screwed spindle connected to said external wall.
In another preferred embodiment of the present invention, by changing the distance between the hinge point and the ring gear center, during the rotation of the planet carrier, in order to provide the movement of the hinge point in different orbits, the subject matter invention comprises additional hinge points on the main planet gear, whereon the rod arm will be hinged.
In another preferred embodiment of the present invention, there is a mechanism body with slots so as to comprise at least some of the main planet gear, planet carrier and the ring gear.
In another preferred embodiment of the present invention, said planet carrier comprises a narrow part connected to the main planet gear in a rigid manner and a wide part wherein the main and support planet gears and the sun gear are bedded, each of which has a hollow structure.
In another preferred embodiment of the present invention, said ring gear has a structure like a ring.
In another preferred embodiment of the present invention, the invention is used in a press or in an inner combustion motor.
The structural and the characteristic features and all the advantages of the subject matter invention can be understood more precisely by means of the detailed explanation which is written with references to these figures and therefore, it had to be evaluated with the detailed explanation and figures that are explained below.
BRIEF DESCRIPTION OF THE FIGURES
In FIG. 1 , the perspective view of the subject matter mechanism is given.
In FIG. 2 , the exploded view of the subject matter mechanism is given.
In FIG. 3 , the cross sectional view of the subject matter mechanism is given.
In the figures between FIGS. 4 a and 4 e , representative figures illustrating the operation characteristics of the subject matter mechanism are given.
In FIG. 4 f , representative figures illustrating the operation characteristics of the subject matter mechanism with respect to different hinge point positions are given.
In the figures between FIGS. 5 a and 5 e , representative figures regarding the adjustability of the subject matter mechanism are given.
In FIGS. 6 a and 6 b , an example regarding the movement characteristics which the subject matter mechanism illustrates in different thread sizes is given.
DETAILED DESCRIPTION OF THE INVENTION
In this detailed explanation, the subject matter mechanism is explained with references to figures in order to make the subject matter more understandable without forming any restrictive effect. Accordingly, in the explanation below and in the subject matter figures, the subject matter invention is assumed to be applied in providing movement of the ram of a press. However, in alternative embodiments, the subject matter invention can also be used in any field where the rotational movement is required to be transformed into different movements.
With reference to FIGS. 1 and 2 , the subject matter mechanism essentially has a mechanism body ( 10 ) with slots onto which some elements forming the mechanism are placed. On said mechanism body ( 10 ), a planet carrier ( 30 ) is rotatably placed. Said planet carrier ( 30 ) is rotated around the own axis thereof by means of a main planet gear ( 20 ) transferring the drive coming from a drive means to the planet carrier ( 30 ). Said planet carrier ( 30 ) carries the gears which are positioned in a similar manner to the planet gear group on the other lateral surface and whose details will be given later. At the continuation of the planet carrier ( 30 ), there is a ring gear ( 40 ) on the mechanism body ( 10 ), which is positioned rotatably. Said ring gear ( 40 ) has an annular structure and preferably both of the inner wall and the external wall thereof have a geared structure. Said inner wall is connected to the gears ( 50 , 60 , 80 ) realizing the planet gear function in the inner wall gear group.
The mechanism body ( 10 ) has a structure similar preferably to a rectangular prism. On the mechanism body ( 10 ), there is a main planet gear slot ( 11 ) in semi-circular form where the half of the main planet gear ( 20 ) is placed. With reference to FIGS. 2 and 3 , said planet carrier ( 30 ) comprises a wide part ( 121 ) with a hollow cylindrical structure so as to define a cross section similar to a T shape and a narrow part ( 32 ) extending at the continuation of said wide part ( 121 ). Accordingly, also the mechanism body ( 10 ) has a planet carrier slot ( 12 ) with a structure so as to be compliant with the form of the bearing and with a size where half of the planet carrier ( 30 ) can be placed. At the continuation of said planet carrier slot ( 12 ), a ring gear slot ( 13 ) with a semi-circle form where half of the ring gear ( 40 ) is placed is formed.
The connection aperture ( 22 ) of the main planet gear ( 20 ) is placed into the narrow part ( 32 ) of the planet carrier ( 30 ). During assembly, the wedge slots ( 21 , 321 ) formed on the external circumference of the inner part of the connection aperture ( 22 ) are corresponded to each other, and by means of the wedges (not illustrated in the figure) placed into these slots ( 21 , 321 ), a rigid connection between the main planet gear ( 20 ) and the planet carrier ( 30 ) is obtained, thus, the planet carrier ( 30 ) rotates together with the main planet gear ( 20 ).
Said gears positioned so as to form a similar structure with the planet gear group; comprise a main planet gear ( 50 ) connected with the gear inner wall of the ring gear ( 40 ); two support planet gears ( 60 ) and a sun gear ( 70 ) which is connected to said three gears ( 50 , 60 ) and which is positioned in the middle. Both the support planet gears ( 60 ) and the sun gear ( 70 ) have a pinion gear structure, the main planet gear ( 50 ) is in annular gear form which has a bearing opening ( 52 ) in the middle. Accordingly, on the lateral surface of the wide part ( 31 ) of the planet carrier ( 30 ), there are 4 bearing slots ( 311 , 312 , 313 ) where one of them is not illustrated in the figures and whereon the gears ( 50 , 60 , 70 , 80 ) forming said gear group are bedded. Preferably three of said bearing slots ( 311 , 312 , 313 ) are close to the external circumference of the wide part ( 121 ) so as to define the corners of a triangle and the other is embodied so as to be in the middle region of the wide part ( 121 ).
Accordingly, the gears ( 50 , 60 , 70 , 80 ) are connected to the planet carrier ( 30 ) by means of gear bearings ( 53 , 61 , 71 ) which are placed into said bearing slots ( 311 , 312 , 313 ) and where one is not illustrated in the figures. Preferably, there are wedge slots ( 314 , 531 ) on the main planet gear ( 50 ) bearing ( 53 ) and on the bearing slot ( 313 ) where this bearing ( 53 ) is placed, and thanks to this, a rigid connection is formed between the two members. On the other hand, the bearings ( 61 , 71 ) of the other gears ( 60 , 70 , 80 ) can freely rotate inside the own bearing slots ( 311 , 312 ) thereof. However, in alternative embodiments, there may also be a wedged connection between all of the bearings ( 61 , 71 ) and the bearing slots ( 311 , 312 ). On the other hand, on the lateral surface of the main planet gear ( 50 ), preferably in a region close to the external circumference, there is an arm hinge point ( 51 ) which has a tabular form and whereon the rod arm ( 100 ) is connected so as to be able to move. The rod arm ( 100 ) comprises an upper hinge slot ( 101 ) on the upper end thereof where the hinge point ( 51 ) is placed and a lower hinge slot ( 102 ) on the lower end thereof wherein a load ( 110 ) is hinged.
As a result, thanks to the support gear group comprising the sun gear ( 70 ) and the planet support gears ( 60 , 80 ) provided in addition to the main planet gear ( 50 ), in applications like press, the axial forces arriving to the arm hinge points ( 51 ) are distributed on said gears, thus a mechanism which is much firmer, much more stabile and which can function with high tonnages is provided. In alternative embodiments, the number of the support gear groups can be increased in an extent that the dimensions of the ring gear ( 40 ) permit. In such a case, there should be no contact between the gears in one support gear group and the gears in another support group.
In a preferred embodiment of the subject matter invention, the main planet ( 50 ) gear is bigger than the other gears ( 50 , 60 , 70 , 80 ) and it has a diameter equal to the half of the ring gear ( 40 ). However, the sun gear ( 70 ) is not concentric with the ring gear ( 40 ). Thus, a planet gear mechanism arises which is not concentric and symmetric and thanks to this structure, rotational movement can be transformed into linear movement. On the other hand, in alternative embodiments, provided that the desired movement characteristic is obtained, the dimensions and their relative sizes of the gears can be changed. For instance, in an alternative embodiment, the main planet gear ( 50 ) can be so as to have a diameter which is smaller than or equal to the diameters of the support planet gears ( 60 , 80 ). With reference to FIGS. 6 a and 6 b , in case the main planet ( 50 ) and the support planet gears ( 60 , 80 ) have equal diameters, for instance, the ram of a press realize a short distance hitting movement at the bottom and at the top point.
The representative views of this embodiment and the operating type are given in the figures between FIGS. 4 a and 4 e . As can also be seen from these figures, when the planet carrier ( 30 ) rotates clockwise when the hinge point is in a position ( 51 1 ), the hinge point ( 51 ) on the main planet gear ( 50 ) passes from the top point to the bottom point by following a linear route (Y 1 ) after a half tour of 180 degrees. When the planet carrier ( 30 ) completes the tour after rotating 180 degrees more, the hinge point ( 51 ) will return to the beginning position by moving in a linear direction from downwards to upwards.
In more details, when the main planet gear ( 20 ) is rotated by means of a motor (not illustrated in the figure), the planet carrier ( 30 ) connected to it and the gears ( 50 , 60 , 70 , 80 ) on the planet carrier ( 30 ) realize an orbital movement in the same direction. On the other hand, during this movement the ring gear ( 40 ) is in fixed position, all of the other gears ( 50 , 60 , 70 , 80 ) rotate around themselves in the direction of the arrows illustrated in the related figures. On the other hand, during this movement, for instance in a press application, in the bottom point, the response force arising when the press head (ram) hits the material is distributed to the sun gear ( 70 ) and the support gears ( 60 , 80 ) through the arm hinge point ( 51 ), from there it is distributed onto the remaining elements, thus the affect arriving to the arm hinge point ( 51 ) is minimized.
As a novelty of the subject matter invention, by changing the position of the arm hinge point ( 51 ) on the main planet gear ( 50 ), the movement characteristics can also be changed. Accordingly, the routes (Ya, Yb, Yc, Yd, Ye) are illustrated in FIG. 4 f which the hinge point ( 51 ) will follow with respect to the 5 different positions ( 51 a , 51 b , 51 c , 51 d , 51 e ) selected on the main planet gear ( 50 ). Accordingly, in the furthest position ( 51 a ) from the main planet gear ( 50 ) center, the hinge point ( 51 ) will follow a linear route (Ya) while the planet carrier ( 30 ) rotates, the hinge point ( 51 ) will follow elliptical orbits (Yb, Yc, Yd), which are gradually bulging, at the positions ( 51 b , 51 c , 51 d ) selected which are closer to the center and finally, in the position ( 51 e ) selected in the center of the main planet gear ( 50 ), the orbit the hinge point ( 51 ) follows is naturally a circle (Ye).
Particularly, when the hinge point ( 51 ) is in position 51 a , when the linear route (Ya) obtained and the axis (E) of the guide ( 111 ) are coincided, the relative rotation movement between the rod arm ( 100 ) and the car ( 110 ) to which this arm is hinged is set to zero. Thus, in presses, by providing the ram and the rod arm ( 100 ) to behave as one rigid piece, a firm structure is obtained. Moreover, thanks to this, since hinge elements will not be used in the connection point, the lubrication and heating problems and the hinge costs are eliminated. In a similar manner, for instance, in inner combustion motors, the movement of the rod together with the piston as a whole eliminates the lateral forces on the piston, thus a shorter rod can be used when compared with classic crank-connection rod mechanisms. With the usage of this mechanism, the classical crank-shaft design will also change.
In the subject matter invention, it is possible to adjust the movement distance (L) of the rod arm ( 100 ). In this adjustment process, the main planet gear ( 50 ) is rotated around itself to the desired extent, the distance between the hinge point ( 51 ) and the ring gear ( 40 ) center and the relative position of the hinge point ( 51 ) with respect to the guide axis (E) changes. Accordingly, preferably a screwed spindle is connected to the recesses in the external circumference of the ring gear ( 40 ), thanks to this, the ring gear ( 40 ) is rotated around itself at the desired angle, thus, the main planet gear ( 50 ) rotates at a certain extent around itself. On the other hand, in alternative embodiments, this adjustment process can also be realized using completely different mechanisms with a structure so as to rotate the ring gear ( 40 ) somehow.
For instance, with reference to the figures between FIGS. 4 a and 4 e , when the hinge point is taken to the position ( 51 2 ), the route (Y 2 ) it follows has an angle with respect to the guide axis (E), thus it becomes shortened. In a similar manner, with reference to FIGS. 5 a and 5 b , when the ring gear ( 40 ) is in the furthest position to the center thereof, the hinge point ( 51 ) follows a long elliptical orbit in the orthogonal direction, thanks to this, in the orthogonal axis, maximum movement distance (Dmax) is obtained. With reference to the figures between FIG. 5 c and FIG. 5 e , when the main planet gear ( 50 ) is rotated 180 degrees, the hinge point ( 51 ) reaches the closest position to the center of the ring gear ( 40 ), thanks to this, it follows a long elliptical orbit in the horizontal direction, thus, the movement amount (C) of the rod arm ( 100 ) is decreased from the longest to the shortest (Dmin).
As a result, thanks to this structure, for instance, the movement distance (C) of the ram part and the upper mould of a press can be adjusted easily with respect to the application regions. For instance, the movement distance (C) of a press can be adjusted to the minimum when work is desired to be realized with stepped mould which requires low course and high velocity, and this distance can be adjusted to maximum when press operations like deep drawing are desired to be realized. Moreover, thanks to the subject matter mechanism, a movement distance can be obtained which is equal to the diameter of the biggest gear in the mechanism, in other words, ring gear ( 40 ) in the mechanism. This brings a very serious advantage when compared with the present presses operating with crank-connection rod where a maximum movement distance equal to the radius of the eccentric gear is obtained.
The protection scope of the present invention is set forth in the annexed Claims and cannot be restricted to the illustrative disclosures given above, under the detailed description. It is because a person skilled in the relevant art can obviously produce similar embodiments under the light of the foregoing disclosures, without departing from the main principles of the present invention.
|
The invention relates to a movement transformation mechanism comprising a main planet gear ( 20 ); a planet carrier ( 30 ) which rotates together with said main planet gear ( 20 ); a ring gear ( 40 ) which is positioned at the continuation of said planet carrier ( 30 ) independent of the planet carrier ( 30 ) and which has at least an inner surface with a gear structure and a main planet gear ( 50 ) which is rotatably connected to the planet carrier ( 30 ) and whose thread is in contact with the thread on the inner surface of the ring gear ( 40 ) and whereon the rod arm ( 100 ) is hinged. In said mechanism, the diameter of said ring gear ( 40 ) is at least two times greater than the diameter of the main planet gear ( 50 ) provided that the diameter ratio is always an integer.
| 5
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from U.S. Provisional patent application Ser. No. 60/000,919, filed Jul. 6, 1995.
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention pertains to a method and apparatus for maintaining an electric iron power cord away from the working or application space of an ironing board or iron during ironing of clothes.
2. Discussion of Prior Art
Generally, electric irons have become a common household appliance frequently utilized to enhance the appearance of various types of clothing by removing wrinkles and/or creases. Irons are typically utilized atop an ironing board and have electric cords of substantial length to connect the irons to conventional wall outlet jacks. However, the electric power cord length often presents various impediments to an operator when ironing clothes. For example, the cord often engages the ironing board edge, becomes entangled, or intercepts the path of the iron during ironing operation. These impediments result in lower efficiency and prolonged ironing times because the power cord and the clothes must be repositioned such that the cord does not interfere with the ironing process. Further, roaming power cords may present a fire hazard should the hot iron contact the cord and erode the electrical insulation surrounding electrical wires disposed in the cord. In short, lengthy electrical power cords tend to interfere with the free and unrestricted use of irons.
There are numerous prior art attempts to obviate the aforementioned shortcomings of the electric cord by utilizing devices to restrict cord movement during ironing. For example, Matthews (U.S. Pat. No. 1,665,316) discloses a device that attaches to an ironing board and has a loop through which the electric iron cord passes. A weight is suspended from the cord at a location between the loop and an electrical outlet jack to maintain the cord taut. Bullock et al (U.S. Pat. No. 1,282,040) disclose a support adapted to be connected to the handle of an iron to support an electric cord and maintain it away from the ironing board to reduce interference with items being ironed. Alvarez (U.S. Pat. No. 4,612,717) discloses a retaining guide in the form of a ring for receiving an electric cord while a weight maintains the cord taut. The attachment of the cord to the iron keeps the cord in an orientation directed upwardly and away from the iron. Edwards (U.S. Pat. No. 2,897,616) discloses an adjustable attachment for an ironing board extending beyond the edge of the ironing board in a C-shape to restrict cord movement. A weight is suspended from the cord to maintain it taut. The attachment is adjustable to accommodate various ironing board widths, and includes hinges to enable the C-shaped cord guide to fold over the ironing board for storage.
The prior art suffers from several disadvantages. The cord guides are typically attached via clamps having a screwing mechanism which must be turned to secure the guide to the ironing board, thereby requiring substantial time for set-up and/or repositioning the guide during different parts of the ironing process. Further, the weights are not secured but instead slide along the cord and tend to bump into various objects (e.g., the ironing board, wall, operator's leg, etc.) during operation of the iron. Moreover, the cord guides are typically made of metal, thereby incurring substantial costs and weight. In addition, cord supports attached to the iron are difficult to install, obtrusive, and may not be pre-installed during iron manufacture.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to improve ironing efficiency by restricting electric iron cord movement during ironing such that the iron power cord does not become entangled with itself or clothes, slide along the edge of the ironing board, or interfere with the iron.
It is another object of the present invention to improve ironing efficiency by restricting electric iron cord movement during ironing via a simple, inexpensive, lightweight and easily transportable and/or attachable cord guide and weight capable of being mounted at numerous positions on an ironing board (i.e., on the ironing board itself or on an ironing board cover disposed on the ironing board) and iron power cord, respectively, to accommodate various items being ironed.
Yet another object of the present invention is to restrict electric iron cord movement during ironing by means of a weight secured to the cord such that the weight maintains its position on the cord and maintains the cord taut in a straight line along the ironing board surface between the iron and an edge of the ironing board.
Still another object of the present invention is to minimize electric iron power cord interference during ironing via an inexpensive, easily attachable and/or pre-installed cord support maintaining the cord away from the ironing workspace.
The aforesaid objects are achieved individually and in combination, and it is not intended that the present invention be construed as requiring two or more of the objects to be combined unless expressly required by the claims attached hereto.
According to the present invention, an iron power cord tension control method and apparatus is accomplished by a pair of spring clips. A guide clip is utilized as a cord guide to restrict movement of an electric iron cord during ironing. This clip is attached to an edge and/or cover of an ironing board and includes a guide element in the form of an arc or loop located on an exterior surface of the clip through which the power cord passes to connect to a wall outlet jack. The guide limits transverse cord movement such that the cord is maintained at a fixed location extending over the ironing board edge (i.e., the cord does not move or "creep" over a corner or otherwise along an edge of the ironing board) and does not interfere with the iron workspace during ironing.
The second or weight clip is utilized as a weight and is attached directly to, and suspended from, the power cord at a location between the guide clip and the wall outlet jack. The weight clip acts as a tensioning device in that it maintains the cord taut between the iron and an end of the guide clip by removing cord slack during ironing.
The clips may be plastic spring clips having two members resiliently biased closed by a metal spring disposed between the two members. Each member includes a substantially rectangular jaw and a rounded handle extending from the approximate center of the jaw. Compressing the handles toward one another opens the jaws which resiliently close upon release of the handles. The jaws may include teeth or serrated edges to enhance gripping of the ironing board, cover or cord. Alternatively, the spring clip may be a single piece of resilient material bent to form two jaws biased closed with similar handles for opening the jaws.
A cord support may be attached to the iron to elevate and maintain the iron cord away from the ironing workspace. The support typically includes a slotted plastic or rubber tube which surrounds the proximal end of the cord adjacent the iron handle. A projection extending downwardly (i.e., distally) from the distal end of the tube along a rear side of the iron (i.e., the side adjacent the proximal end of the handle) maintains the tube in an erect state to elevate the cord. The support may be secured to the cord via a cable tie after purchase of the iron, or alternatively, may be pre-installed as a thick collar during manufacture of the iron. Cord interference may be reduced by utilizing the cord support either alone or in conjunction with the cord guide and weight clips described above.
The above and still further objects, features and advantages of the present invention will become apparent upon consideration of the following detailed description of a specific embodiment thereof, particularly when taken in conjunction with the accompanying drawings wherein like reference numerals in the various figures are utilized to designate like components.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view in perspective of the cord tension control apparatus of the present invention attached to an ironing board and iron.
FIG. 2a is a top view in plan of a clip employed by the cord tension control apparatus of the present invention.
FIG. 2b is a side view in elevation of a clip employed by the cord tension control apparatus of the present invention.
FIG. 3 is a view in perspective of the cord tension control apparatus of FIG. 1 employing a cord support on the iron according to the present invention.
FIG. 4 is a view in perspective of a cord support according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A tension control apparatus for preventing electric iron power cords from interfering with an operator ironing clothes is illustrated in FIG. 1. Specifically, a conventional iron 4 is disposed on a substantially horizontal top or working surface 18 of an ironing board 2. Ironing board 2 may include a conventional ironing board cover (not shown) and is illustrated as an isolated unit having a vertical ledge 36 disposed about its perimeter and extending downwardly from the peripheral edge of horizontal surface 18. Diagonally oriented collapsible legs 16, 17 extend generally downward from the underside of the board and collapse to facilitate ironing board storage. Ironing board 2 has a conventional configuration with a substantially rectangular proximal section merging into a distal section wherein the board width tapers distally. The distal section occupies approximately the distalmost one-third of the ironing board and has a rounded distal end. The illustrated ironing board is conventionally configured; however, the present invention is applicable to all ironing boards or other substantially horizontal surfaces where ironing may be performed (e.g., tables, ironing boards attached to walls, etc.). Iron 4 typically includes a flat base surface 11 for applying heat and/or steam to clothes, a handle 12 disposed adjacent the base and extending longitudinally along the iron, and an electric cord 6 extending from the proximal end of the handle. Electric cord 6 includes a plug (not shown) at its distal end for insertion into a conventional wall outlet jack, and a flexible collar 14 at its proximal end to insulate and protect electrical wires disposed in the cord.
Various types of clothing are generally placed flat on working surface 18 of ironing board 2, and iron 4 is gripped via handle 12 with base surface 11 pressed against the clothing. The iron is then moved about over the clothing to remove wrinkles and or creases. As iron 4 traverses the clothing, attached power cord 6 follows the iron and may, if not otherwise restrained, become slack and bunch up on surface 18, thereby tending to become entangled with itself or the clothing and interfering with the ironing process. In order to restrict such movement of power cord 6, a guide clip 8 and a weight clip 10 are disposed on ironing board 2 and power cord 6, respectively. Specifically, guide clip 8 includes two pivotably engaged gripping members 20, 22 having respective distal jaws 24, 28 and proximal handles 26, 30. Members 20, 22 are resiliently biased to pivot to a closed position (i.e., jaws 24, 28 forced together) by a metal spring 32 disposed between handles 26, 30. Jaws 24, 28 are substantially rectangular with a relatively long dimension parallel to the pivot axis, and a significantly shorter dimension perpendicular to that axis. The jaws may include teeth or a serrated distal edge to enhance gripping. Handles 26, 30 respectively extend from the approximate center of jaws 24, 28 in a direction either generally perpendicular to the pivot axis, or at lesser and opposing angles (i.e., angles less than ninety degrees) such that the handles are separated by a proximally increasing distance. The handle width (i.e., the dimension parallel to the pivot axis) is considerably shorter than the handle length. Jaws 24, 28 include rounded proximal corners adjacent handles 26, 30. The long dimension of the jaws is preferably about one-quarter the width of the proximal end of ironing board 2. Handles 26, 30 have a shorter dimension substantially similar to the shorter dimension of jaws 24, 28, while the longer dimension of the handles are approximately one and one-half times the shorter dimension of the jaws. By way of example only, jaw 24 includes a cord guide 34 disposed on the exterior surface of the jaw, however, either jaw may include the cord guide. Cord guide 34 preferably takes the form of a bar or rod with right angle bends proximate its ends to form a flattened U-shape. The ends of the bar are secured to the exterior surface of jaw 24 to define a rectangular guide space between the bar and the jaw surface. The rod may be of any transverse cross-sectional shape (e.g., polygon, circle, ellipse) and extend parallel to the jaw surface for any desired length, preferably as long as possible to permit the power cord maximum freedom of transverse movement in the guide 34. The spacing between the bar and the exterior surface of jaw 24 must at a minimum be slightly greater than the dimensions of a conventional plug disposed at the distal end of cord 6 such that the plug and cord may be inserted longitudinally through cord guide 34. Alternatively, cord guide 34 may include a small opening in the bar to permit cord 6 to be inserted transversely through the opening into the confines of the guide. In this case, the opening may include a resilient or other latch to maintain the cord within the confines of the guide, and the distance between the bar and the exterior surface of jaw 24 may be any distance capable of receiving the cord. Power cord 6 is disposed through cord guide 34 such that the cord guide restricts transverse cord movement to the distance defined by the cord guide length.
Guide clip 8 may be disposed on ironing board 2 by applying a force to pinch handles 26, 30 together in opposition to the bias of spring 32, thereby opening jaws 24, 28 (i.e., moving jaws 24, 28 apart) until the distance between the jaws is greater than the thickness of vertical ledge 36. Guide clip 8 may then be positioned at any location along ledge 36 with jaws 24, 28 encompassing, and handles 26, 30 extending downwardly from, the ledge. The force opposing the spring bias is subsequently removed to enable the jaws to close and engage the ledge. The guide clip may be moved to any location along ledge 36 during an ironing procedure to facilitate positioning of the iron on the garment being pressed. Alternatively, guide clip 8 may be manipulated as described above to enable jaws 24, 28 to engage a conventional ironing board cover (e.g., in the case where the guide clip cannot engage the ledge) disposed on ironing board 2. Guide clip 8 may be positioned at any location on the cover suitable for facilitating positioning of the iron on the garment being pressed.
Weight clip 10 is substantially similar to guide clip 8 except that the weight clip does not include a cord guide. Clip 10 includes two pivotably engaged gripping members 38, 40 each having a jaw 42, 46 and handle 44, 48, respectively. Members 38, 40 are resiliently biased to pivot to a closed position by a metal spring 50 disposed between the members. Jaws 42, 46 are generally similar to jaws 24, 28; handles 44, 48 are generally similar to handles 26, 30; and members 38, 40 are generally similar to members 20, 22. In the preferred embodiment the longer dimension of jaws 44, 48 of weight clip 10 is greater than the corresponding longer dimension of jaws 24, 28 of guide clip 8. This longer length provides greater weight to maintain cord 6 taut.
Weight clip 10 may be disposed on cord 6 by applying force to pinch handles 44, 48 together in opposition to the bias of spring 50, thereby opening jaws 42, 46 until the distance between the jaws is greater than the diameter of cord 6. Clip 10 may then be positioned at any longitudinal point along cord 6 between guide clip 8 and a wall outlet jack such that clip 10 is suspended from the cord above the floor. The weight of clip 10 pulls on the power cord to keep it taut along the working surface. Care should be taken when placing clip 10 on the power cord to make sure that it does not contact guide clip 8 or the floor during ironing. Since the dimensions of clip 10 (i.e., the longitudinal length of the jaws and transverse length of the clip) are greater than the area enclosed by cord guide 34 of clip 8, cord guide 34 can block clip 10 should clip 10 be drawn into contact with clip 8. Blocked clip 10, being attached to cord 6, prevents power cord 6 from sliding through cord guide 34 and therefore inhibits movement of the iron. On the other hand, contact by clip 10 with the floor renders the weight clip ineffective to keep the power cord taut, thereby permitting the cord to bunch up and become entangled. When open, jaws 42, 46 encompass cord 6 at the desired cord position. The force opposing the bias of spring 50 is removed to enable the jaws to close and engage the cord. Clip 10, in effect, acts as an anchor and utilizes its weight to remove slack and maintain cord 6 taut in a substantially straight line from the iron to cord guide 34. Since clip 10 engages power cord 6, movement of the cord with the iron 4 causes the clip to move up and down with the suspended cord to keep the cord taut.
Clips 8, 10 may be conventional clips substantially similar to clips utilized to reclose potato chip or other snack bags, and employ a spring to resiliently bias the clips closed as illustrated in FIGS. 2a-2b. By way of example only, the spring is described with reference to weight clip 10, however, guide clip 8 functions in substantially the same manner. Metal spring 50 is disposed between members 38, 40 coincident handles 44, 48, such that the longitudinal axis of the spring (i.e., the pivot axis) is parallel to the longer dimension of jaws 42, 46, and the shorter dimension of the handles. The pivot axis of clip 10 may be located at any point along the longer dimension of handles 44, 48 capable of enabling the clip to be securely disposed on the cord. For example, the pivot axis may reside at the proximal end of handles 44, 48 when the handles extend from jaws 42, 46 at opposing angles and are separated by a proximally increasing distance. Alternatively, handles 44, 48 may include projections (not shown) extending transversely from the interior surfaces of the handles at various locations along the longer dimension of the handles. The projections engage each other between handles 44, 48 to separate the handles and form the pivot axis. Spring 50 is typically a metal wire having five consecutive substantially perpendicular sections. An intermediate section 55 is disposed between members 38, 40 while the ends of the wire extend from the intermediate section around respective handles 44, 48 to engage an outwardly facing exterior surface of each handle. Specifically, the wire extends from intermediate section 55 along the shorter dimension of jaws 42, 46, in opposing directions, and bends approximately ninety degrees subsequent to reaching the exterior surface of a respective handle 44, 48 to form respective arms 52, 54. Arms 52, 54 extend substantially the entire shorter dimension of respective handles 44, 48 and apply force (i.e., a bias force) from spring 50 to the base of the handles to maintain jaws 42, 46 closed. The spring may be implemented by any spring arrangement or resilient device capable of providing bias to maintain the members closed. Alternatively, the jaws may be made from one piece of spring metal, much like bulldog clips used to clip papers together.
An alternative embodiment, for supporting power cord 6 to extend it upward and away from the ironing workspace is illustrated in FIGS. 3 and 4. The iron cord tension apparatus is substantially similar to the apparatus described above for FIGS. 1, 2a, 2b except that iron 4 includes cord support 56 for extending cord 6 above working surface 18. Specifically, cord support 56 is disposed over the proximal end of cord 6 at the iron handle 12 where cord 6 extends from the iron. Support 56 is typically a rigid or semi-rigid plastic or rubber tube having a substantially cylindrical section 62 with a longitudinal slot 58 extending along the entire length of the section. However, the support may be implemented by a tube having any cross-sectional shape (e.g., circle, polygon, ellipse) capable of fitting around the proximal end of cord 6. A projection 64 extends downwardly (i.e., distally) from the distal end of section 62 angularly offset approximately one-hundred eighty degrees from slot 58. The width of projection 64 typically tapers distally to form a rounded distal end, however, the projection may be of any shape capable of elevating cord 6 as described below. Support 56 has a diameter slightly greater than the diameter of cord 6, and has a length of approximately six inches, although the length is not critical so long as the support serves its described function. Cord 6 may be transversely inserted through slot 58 such that support 56 surrounds the cord to rigidify and elevate the cord above horizontal surface 18 and minimize interference by the cord during ironing. Support 56 may be secured about cord 6 via a cable tie 60 or the like. The distal end of section 62 rests on the top surface of handle 12 while projection 64 extends downwardly from the handle against the rear side of the iron (i.e., the side adjacent and extending downwardly from the proximal end of the handle). Projection 64 opposes the gravitational forces applied by cord 6 and enables support 56 to remain upright and elevate the cord. Alternatively, support 56 may be pre-installed as a thick rubber collar during manufacture of the iron and function as described above. Cord interference may be reduced by utilizing support 56 either as a stand-alone unit, or in conjunction with guide clip 8 and weight clip 10 in substantially the same manner described above.
Operation of the present invention is described with reference to FIGS. 1, 3 and 4. Initially, an ironing board 2 is removed from storage and assembled with iron 4 placed on working surface 18. Guide clip 8 is attached to vertical ledge 36 (for example, at the proximal end or at a side) of the ironing board such that cord guide 34 extends horizontally outward or away, and handles 26, 30 extend downwardly, from the ledge. Clip guide 8 is attached to ironing board 2 by applying pinching force to handles 26, 30 to oppose the bias of spring 32 and separate jaws 24, 28. Jaws 24, 28 are then positioned on opposite sides of ledge 36 such that, when the force opposing the spring bias is removed, the jaws close on and engage ledge 36. Alternatively, guide clip 8 may be attached to a conventional ironing board cover disposed on ironing board 2 in substantially the same manner described above. Cord 6 extends through cord guide 34 and is connected to a wall outlet jack. Weight clip 10 is then attached to cord 6 at a location between cord guide 34 and the wall outlet jack. The preferred location for weight clip 10 is a point where the clip will not engage guide clip 8 or the floor during ironing so that the weight clip maintains the cord taut. Weight clip 10 is attached in substantially the same manner described above for guide clip 8 by applying pinching force to handles 44, 48 to oppose the spring bias and open jaws 42, 46, positioning the cord between the jaws at a desired location, and then removing the force to enable the jaws to engage the cord. After the guide and weight clips 8, 10 are positioned, ironing may commence with cord 6 maintained taut and its movement restricted to minimize interference with iron 4 and the clothes.
The preferred location for cord guide 34 during ironing is at the proximal end of the ironing board. It will be appreciated that the guide can be easily moved to different locations along ledge 36 or on the ironing board cover to facilitate ironing various garments or different pads of a garment or item. Further, cord guide 34 may engage the ironing board, ironing board cover, or combination of the ironing board and cover to restrict iron cord movement.
When cord support 56 is attached to cord 6 at the proximal end of iron handle 12, the support elevates and maintains cord 6 above the ironing workspace on surface 18 to further reduce cord interference during ironing.
Cord support 56 may be utilized in conjunction with or without guide and weight clips 8, 10. When they are used together, cord support 56 elevates and maintains cord 6 above the ironing workspace while guide clip 8 and weight clip 10 respectively restrict cord movement and maintain the cord taut to minimize cord interference with the iron.
It will be appreciated that the embodiments described above and illustrated in the drawings represent only a few of the many ways of implementing an iron cord tension control system. The important aspects of clips 8 and 10 are that they are quickly and easily attached to the ironing board and/or ironing board cover and power cord in a variety of orientations and at a variety of locations. The quick and easy installation of the clips permit them to be moved easily to accommodate various garments during an ironing operation without a significant expenditure of time as required by screw attachments and the like.
The clips of the present invention may be any clips or grasping devices including a guide to restrict cord movement. The clips may be constructed of wood, plastic, metal or other sturdy material, and include a spring or other bias or resiliency device to bias the clips closed. The weight clip may be implemented by any device capable of being suspended from, or disposed on, the cord and being of sufficient weight to maintain the cord taut. The guide clip may be positioned at any orientation and at any point along the perimeter of the ironing board and/or ironing board cover capable of reducing cord interference during ironing. The present invention may be utilized on any ironing board or horizontal surface having an area for the guide clip to engage. The cord guide may be implemented by rods, of any shape forming loops or guides of any size capable of confining cord movement to a specified area. The jaws of the guide and weight clips may be dull, have teeth, or have serrated edges to enhance the gripping capabilities. The cord support may be constructed of rubber, plastic, or other sturdy material capable of elevating the cord above the working space. The cord support may be implemented by any rigid or semirigid tube and may be secured by cable tie or other securing mechanism capable of securing the support to the cord.
Although the preferred embodiment of the invention utilizes a vertical ledge 36 as the attachment structure for clip 8, it is to be understood that the clips can be sized to attach to an ironing board peripheral edge having no such ledge, or be attached to a conventional ironing board cover disposed on the ironing board. In this regard, the invention involves quick and simple attachment and/or relocation of guide 34 by means of a spring loaded clip and is not limited to any particular ironing board or cover or any particular orientation (i.e., vertical) of the ironing board structure and/or cover to which clip 8 attaches.
It is to be understood that the principles of the present invention may be accomplished by any clip devices capable of guiding an electric cord and weighing the cord down to remove slack, or devices capable of elevating and maintaining the cord above the workspace. Further, the principles of the present invention may be applied to appliances, power tools, or other electric devices to prevent cord interference and potentially hazardous situations from accidental cord contact.
From the foregoing description it will be appreciated that the invention makes available a novel iron cord tension control method and apparatus wherein a guide clip having a cord guide is disposed on an ironing board and a weight clip is disposed on the electric iron cord subsequent to traversing the cord guide to restrict cord movement during ironing and reduce cord interference.
Having described preferred embodiments of a new and improved iron cord tension control method and apparatus, it is believed that other modifications, variations and changes will be suggested to those skilled in the art in view of the teachings set forth herein. It is therefore to be understood that all such variations, modifications and changes are believed to fall within the scope of the present invention.
|
Electric iron power cord tensioning is accomplished by a pair of clips. A guide clip includes a looped member to receive and restrict cord transverse movement to the area defined by the looped member. The guide clip resiliently attaches to the periphery of the working surface of an ironing board and/or to the periphery of the ironing board defined by an ironing board cover with the looped member extending outwardly from the ironing board. A weight clip resiliently engages and is suspended from the cord subsequent to the guide clip to pull the cord and maintain it. Cord interference with the iron during ironing is reduced since the cord is prevented from bunching up and becoming entangled with or obstructing the iron. Alternatively, a cord support may be disposed about the power cord adjacent the iron handle to elevate and maintain the cord above the ironing board. The support may be used alone or in combination with the guide and weight clips. The support may be installed either by the end user as a slotted tube, or during manufacture via a rubber collar disposed continuously around the cord adjacent the iron handle. The support maintains the cord above the working space and thus reduces cord interference during ironing.
| 3
|
[0001] This application claims priority from U.S. Provisional Application Ser. No. 62/362,953 filed on Jul. 15, 2016.
FIELD OF INVENTION
[0002] This invention relates to portable apparatus for sharpening knives, fishhooks and other implements. In greater particularity the present invention relates to such an apparatus that may be hand held or mounted to a firearm using a rail-mounting system. In still greater particularity the apparatus relates to such an apparatus that may also be used as a hand held device or mounted to a surface such as a table, countertop, desk, or movable vehicle.
BACKGROUND
[0003] Other sharpeners have incorporated various ceramic, carbide and/or diamond feature components and configurations, either singularly or collectively, primarily configured for hand-held use. Other sharpeners feature much larger sharpening arrays, either manual or motorized, for tabletop use.
SUMMARY
[0004] This rail-mountable tool sharpener provides direct and immediate six-station access for multi-task sharpening needs in a compact, fold-up housing that is removably attached to a rail-equipped firearm, crossbow, or other device. The rail-arm handle feature quickly deploys the sharpener from its compact, folded storage mode for immediate field sharpening needs with secure control and stability under all field conditions in an off-weapon carry mode, while incorporating the easy carry option of a pocket/vest/gear mounting clip. Both of these deployment modes provide for greater user safety and hand clearance due to their firm and rigid platform stability being attached to a firearm or the rail-mount handle versus a sharpener merely being hand-held. The PALS (Pouch Attachment Ladder System) sharpener carrier clip provides secure mounting for ready-access carry on all load-bearing platforms, such as vests and backpacks. The rail-equipped knife sharpener base allows for safe and stable tabletop sharpening in the kitchen or on a workbench.
[0005] This rail mounted sharpener system is designed to be ultra-compact, incorporating sharpening solutions that exceed any other sharpener, with a mounting configuration that provides safe and ready-access functionality and usage for both the military and civilian markets. This rail mounted sharpener can be mounted on any rail-equipped military or sporting rifle, machine gun, shotgun, crossbow or other such equipped device, or carried on all load-bearing vests and backpacks, or mounted for tabletop use for ready-access knife, tool or fish hook sharpening needs. No other sharpener is as compact for ease of carry nor incorporates as many sharpening options as does this sharpener system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Referring to the drawings which are appended hereto and which form a portion of this disclosure, it may be seen that:
[0007] FIG. 1 is a side elevation view of the rail mounted sharpening device;
[0008] FIG. 2 is an upper perspective view of the rail mounted sharpening device;
[0009] FIG. 3 is an upper perspective view of the rail mounted sharpening device mounted to a rail;
[0010] FIG. 4 is a side elevation view of the rail mounted sharpening device in a closed position;
[0011] FIG. 4A is a side elevation view of the rail mounted sharpening device in a closed position from the side opposite the view shown in FIG. 4 ;
[0012] FIG. 5 is a plan view of the rail mounted sharpening device in a closed position mounted to a rail;
[0013] FIG. 6 is an end view of the rail mounted sharpening device in a closed position;
[0014] FIG. 7 is a side elevational view of a handle and rail for the rail mounted sharpening device;
[0015] FIG. 8 is a side elevation view of the rail mounted sharpening device mounted to the handle shown in FIG. 7 ;
[0016] FIG. 9 is a perspective view of the rail mounted sharpening device in a closed position;
[0017] FIG. 10 is a perspective view of the rail mounted sharpening device mounted to its handle
[0018] FIG. 11 is a perspective view of the rail mounted sharpening device mounted to the rail handle in folded position;
[0019] FIG. 12 is an end view of the rail mounted sharpening device mounted to the rail handle in a folded position;
[0020] FIG. 13 is a side elevation view of the rail mounted sharpening device secured in the PALS configured carrier clip;
[0021] FIG. 14 is a perspective view of the PALS carrier clip;
[0022] FIG. 15 is a perspective view of the rail mounted sharpening device mounted to an integral rail base.
DETAILED DESCRIPTION
[0023] One or more of the above objects can be achieved, at least in part, by providing a multi-station rail mounted multifunctional sharpening device for knife blades, fish hooks, and other implements. Referring to FIG. 1 it can be seen that multiple components are optionally included in the device. In one embodiment of the device, a foldable assembly 10 including a sharpener housing body 101 containing multiple sharpening stations is used. The rotatable sharpener housing body 101 is rotatably mounted to a sharpener housing rail-mounting base 102 that defines a rail receiver 105 therein for selective mounting of the base 102 and rotatable housing body 101 to a rail-mounting system, such as are used on various weapons. In one embodiment, the rail receiver 105 enables the rail-mounting base 102 to be connected to a hand-held handle 20 which includes a handle body 201 and pivoting and locking rail 203 .
[0024] Referring to FIGS. 1 to 6 note that sharpener housing body 101 supports a number of sharpening elements. At one end of the housing body 101 is a diamond hook sharpening panel 104 , which is also shown in FIG. 6 . Sharpening panel 104 is a convex diamond coated plate and includes two tapered diamond coated grooves 126 shown in FIG. 6 . Also mounted in housing body 101 are a pair of fine abrasive ceramic sharpening sticks 106 which are mounted at an angle to each other producing a 20° edge angle on both sides of a knife blade (40° included angle) drawn across the sharpening sticks 106 simultaneously. Near the middle of body 101 , a pair of coarse abrasive ceramic sharpening sticks 107 are also mounted, again at an angle producing a 20° edge angle on both sides of a knife blade drawn across the sharpening sticks 107 simultaneously. Likewise, beveled carbide inserts 108 are mounted at an angle producing a 20° edge angle on both sides of a knife blade carbide inserts simultaneously. Carbide inserts 108 are held in place by insert pins 109 whereas sharpening sticks 106 and 107 are held in place by four flat point socket set screws 121 , shown in FIG. 3 which allow for the removal or rotation of sharpening sticks 106 or 107 if needed.
[0025] Referring to FIG. 1 , a diamond abrasive coated tapered rod 111 is mounted for rotation from within a longitudinal channel in body 101 on pivot pin 113 . Tapered rod 111 which rotates outwardly from the housing for sharpening knife blade serrated edges. The diamond coating on tapered rod 111 only extends to a point just before the area of contact with a retention lip 112 on the housing body 101 . To rotate the rod the user catches the tip of the rod, which extends out beyond the end of the housing, urging it laterally out of the channel and freeing it past the retention lip 112 .
[0026] As may be seen more clearly in FIG. 2 housing body 101 is pivotally mounted to base 102 along an axis extending along a sharpener housing rotation locking screw 123 , which is received in sharpener housing rotation locking screw threaded shaft 119 . The rotation locking screw has a knob end 103 extending from housing body 101 for access to enable the locking screw 123 to be loosened for selective movement between the work position shown in FIGS. 1 to 3 and the closed position shown in FIG. 4 . A modified disc rotation locking wheel 114 is also mounted to base 102 and at can be rotated to lock and unlock the rotation of the housing in both the open (upright) and closed (laid down) positions. The full edge of the wheel 114 rotated vertically along any part of its circumference will block and lock the housing's rotation. To free the rotation, the wheel 114 is rotated until the opposite side of the wheel which has a diminished radius, is turned upwardly, such that it does not contact the housing body 101 and allows movement between the open and closed positions.
[0027] Again as seen in FIG. 2 , sharpener housing rail-mounting base 102 includes an opposing side forming a sharpener housing rail-mounting base clamp 118 which forms the opposite side of rail receiver 105 . A pair of sharpener base rail locking screws 116 pass through the base 102 and receiver 105 and screw into threaded inserts 122 , shown in FIG. 4A . It will be appreciated from FIG. 3 that the rail 140 inserted into receiver 105 is formed with a number of crests and valleys such that the rail locking screws 116 can be inserted to engage appropriate valleys and lock the base 102 to rail 140 in a well-known manner. Of course, the rail and receiver may be locked by other means such as with locking pins as is well known. Rail 140 may be configured a MIL-STD-1913 rail, a 2324 rail, a Picatinny rail, a tactical rail, a Weaver rail, a STANAG 4694 NATO Accessory Rail (NAR), and/or any other rail-mounting platform of similar configuration. It is understood that these rail configurations are well known in the firearms industries and allow the sharpener to be readily mounted to a firearm. As will be discussed further, the sharpener may likewise be rail mounted to objects other than a firearm.
[0028] Referring to FIG. 4 , it may be seen that the housing body 101 folds down on base 102 when mounted for storage on a rail. Referring to FIG. 5 , housing body 101 is shown in its folded position, with tapered rod 111 and retention lip 112 visible above rotating locking screw knob 103 . Diamond hook sharpening panel 104 with two tapered diamond coated grooves 126 is also shown.
[0029] Referring to FIGS. 7 and 8 an optional knife and tool sharpener handle 20 is provided including handle body 201 carrying a sharpener handle pivot pin 202 , on which is mounted the sharpener handle rail 203 , the sharpener handle rail locking wheel 204 , the sharpener handle clip 206 , and the sharpener handle rail locking wheel screw 207 , shown in FIG. 12 , which retains the locking wheel 204 . As may be seen in FIGS. 8, 9, and 10 , the assembly 10 is attached to the sharpener handle rail 203 in exactly the same manner as the assembly is attached to a weapon mounted rail, however, the handle body 201 allows much more maneuverability and ease of use. The assembly 10 may be collapsed or folded as shown in FIGS. 11 and 12 . Rotating locking wheel 204 will allow rail 203 to pivot around pin 202 and the folded assembly 10 may be brought into a stored position resting on detent 208 , shown in FIG. 10 . Locking wheel 204 may then be repositioned to retain the assembly 10 in the stored position.
[0030] Referring to FIGS. 13 and 14 , note that assembly 10 may be secured in the PALS sharpener carrier 301 . The carrier has a detent 302 in the bottom foot 306 that aligns with the opening in the threaded shaft 119 to aid in positioning alignment. When in place, the rotation locking screw 123 , having been removed prior to insertion into the carrier, passes through an alignment hole 303 in the top 305 of the carrier and screws down into the threaded shaft 119 in the sharpener base, securing it to the carrier.
[0031] There is clearance space allowed for between the inside face of the carrier body 304 and the sharpener itself for webbing to pass and be secured to on the PALS grid on vests, packs, etc. To attach the carrier 301 to a vest or pack, the bottom foot 306 of the carrier passes behind the webbing and the carrier is rotated vertically into position to accept the sharpener housing. The radiused cutout 307 in the lower body of the carrier 301 allow for some slight flexing to occur when the base is positioned into engagement.
[0032] Referring to FIG. 15 , it may be seen that the versatile tool may be attached to a mounting pad 401 for use on a table top, on a surface on a vehicle or any other similar mounting platform. Pad 401 has an integral rail 402 that is used to secure the assembly 10 in the same manner as the aforementioned rails and may be likewise configured. It will be readily understood that pad 401 may be conventionally secured or may have a tacky lower surface that prevents its movement while the tool is in use.
[0033] While in the foregoing specification this invention has been described in relation to certain embodiments thereof, and many details have been put forth for the purpose of illustration, it will be apparent to those skilled in the art that the invention is susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing from the basic principles of the invention.
|
A portable tool sharpener adapted for mounting on a rail such as may be found on various weapons includes a sharpener body in which a plurality of sharpening tools are mounted and a rail-mounting base pivotally mounted to the sharpener body to allow the body to moved selectively to a closed and open position, wherein the rail-mounting base is releasably engageable with a rail mounted on a weapon, a handle or a fixed pad.
| 1
|
BACKGROUND OF THE INVENTION
This invention relates to an automated test tool for computer systems and in particular to a test automation tool having dynamic attributes for testing a computing environment.
An important aspect of design and fabrication of any technology is the testing of different features that make up that technology. Testing is not only used for quality control purposes, to ensure the reliability of existing technology, but is also a key requirement when introducing new features or when repackaging existing features in new and improved ways. This is particularly true in the computer industry as it relates to the testing of a computing environment having both hardware and software elements.
A foremost objective in providing testing tools and methodology, especially in the computer industry, is to provide thorough testing. Complex computing environments, which vary in numbers of and types of hardware and software, as well as operating systems and middleware, require many attributes to be tested to ensure system integrity. Systems have become so complex that it is frequently impossible to test all attributes of system organization and function. A challenge of present test methodologies is to be able to identify and test attributes of the system that are most likely to fail, and those that are most critical to its operation. Since system attributes can vary over a range of values, testing sufficient combinations of attributes having different values is difficult without some form of automation. However, test automation as provided by the prior art, has its own set of challenges.
A disadvantage of prior art test automation techniques is that they only test one sub-environment at a time, where attributes and their values are well defined and known. In complex computing environments where the environment includes many applications, configurations and sub-environments, test tools adaptable across the environment are not commonly available. Testing in one sub-environment or configuration alone is undesirable because it does not validate similar testing in other sub-environments or configurations.
In simple computing environments, testing is traditionally accomplished by entering the attributes and values as parameters manually, for example, on a command line for a particular test tool or script. With automation, programs can be designed to test a more inclusive set of values than those permitted by manual testing. The values to be tested in an automation scheme are normally kept in an input file. Automated test tools, therefore, have to be developed beforehand in order to make the input file available at time of test that has the test values to be used. This makes the changing of or incorporation of new attributes into the prior art automated test scenarios very difficult.
In addition, the necessity of choosing values beforehand leads to the problem of not knowing exactly what values need to be included for automated testing. Selecting particular attributes to be varied in different test scenarios for a complex computing environment could lead to an endless number of variations. The prior art automation schemes only cover limited predefined attributes and values, making it difficult to decide upon the right amount of attributes to be tested beforehand in order to ensure accurate test results.
There is a perennial need for automation tools that allow user input to customize a test scenario to particular feature of the system under test. This is because it could be impossible to account for all testing scenarios ahead of time. Often an unanticipated condition or unaccounted for need arises because of certain conditions only occurring during the test. For example, a particular test configuration may be only available in a certain time frame for testing purposes. However, in such instances, there may not be enough time and resources available to alter the test using the changed attributes, such that testing must proceed with pre-existing scenarios that do not adequately cover the computing environment.
Another problem with the existing prior art is that automated test tools are not designed to be flexible. Traditional automation tools only provide for a fixed set of input and output values. Changing a test scenario to expect different parameters, and checking for different results or errors, requires stopping tests at run-time. New input must be manually created before the test is restarted. These limitations hinder the purpose of the automation tool. Another problem relates to requirements that are hard-coded in scripts or in binary formats. In such cases, automated test tools that generate job conditions at run time do not allow the user to change pre-fixed attributes of control commands or to add or remove control commands unless they are defined in the scripts and program source files. This prevents last minute tests from being included, even when they are deemed essential.
Consequently, the designers of test tools for computing environments face many challenges today. Manual testing is tedious and impractical due to the number of test conditions that need to be varied. On the other hand, automation is inflexible under the prior art techniques and cannot be performed adequately across multiple configurations and sub-environments in a complex computing environment. Furthermore, significant time and resource constraints prevent testing of all attribute variations in such an environment. In addition, deciding what to test beforehand is often unfeasible and impractical under the current prior art techniques. Foregoing thorough testing, however, is also not a desirable option as it may lead to unwanted problems and increased risks to product performance. A new test automation tool and methodology is needed to address the above-mentioned concerns.
SUMMARY OF THE INVENTION
According to an aspect of the invention, a test automation tool is provided which is operable to integrate a set of dynamic attributes and values into tests to be performed on a computing environment. The test automation tool includes a job submission engine (JSE) operable to receive input regarding first attributes unchanged from a first computing environment and second attributes representing change from the first computing environment. A job control file generator (JCFG) is provided in electronic communication with the job submission engine and is operable to automatically generate job control files (JCFs) for controlling testing of the computing environment according to attribute values including first attribute values and second attribute values. First attribute values are generated based on an automatic sampling of values of first attributes. The JSE is further operable to automatically submit the JCFs to the computing environment for execution and to automatically monitor execution according to the JCFs.
The recitation herein of a list of desirable objects which are met by various embodiments of the present invention is not meant to imply or suggest that any or all of these objects are present as essential features, either individually or collectively, in the most general embodiment of the present invention or in any of its more specific embodiments.
DESCRIPTION OF THE DRAWINGS
The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of practice, together with further objects and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings in which:
FIG. 1 illustrates process flow for a test automation method according to an embodiment of the invention;
FIG. 2 is a block and schematic diagram illustrating components of a test automation tool according to an embodiment of the invention;
FIG. 3 is a diagram illustrating a job submission engine according to an embodiment of the invention;
FIG. 4 is a flow diagram illustrating operation of a job control file generator according to an embodiment of the invention; and
FIG. 5 illustrates value-setting methods according to embodiments of the invention.
DETAILED DESCRIPTION OF THE INVENTION
According to embodiments of the invention, a test automation tool and method is provided that can be applied flexibly to a broad range of test coverage needs. Such automation tool and method can be applied across computing environments, allowing testing of applications and configurations without regard to whether the computing environment is made up of only a single computer unit or a complex and varied set of networked nodes having a variety of operating systems and applications. In contrast to the test methods of the prior art scenarios, the embodiments of the invention are well adapted to testing of dynamically changing environments where nodes, configurations and applications are being constantly modified, added or removed.
A feature of the test automation tool provided herein is that the user is given the ability to define attributes and their values on which test scenarios will be based. Test needs change dramatically in terms of changes in attributes and their values when there is change in a system, or in more complex environments when moving from one system configuration to the next.
In an embodiment of the invention, a method and a tool for generating dynamic attributes and value sets are provided, as depicted in FIG. 1 . For ease of reference, aspects of an automation tool are hereinafter referenced as the dynamic attributes and values sets integrator or (DAVSI), with the understanding that the name DAVSI shall not be indicative of any restriction, implications or limitations imposed by the choice of words, as other names and variations may be selected, according to the embodiments of the present invention. As depicted In FIG. 1 , testing attributes define the range of functions upon which one or more set of tests will be based and automated. For each selected attribute, as provided in FIG. 1 , specific testing values are then generated for as shown at 115 and 125 .
According to DAVSI, attributes for testing are classified in one of two categories as core attributes and changeable attributes, as shown at 100 . In an embodiment, these attributes are identified and categorized based on job control commands, but users can also define these attributes separately. The core attributes, also called generic attributes, reflect those attributes that are considered to be common and non-changing in a majority and preferably all test cases that are to be generated. By contrast, the changeable attributes, also known as non-generic attributes, represent those attributes that are expected to vary. Changeable attributes further belong to one of two classes, namely dynamic attributes and special attributes. Dynamic attributes frequently change from one test to another for a variety of reasons, not all of them being predictable. Special attributes, also referred to at times as user specific attributes are specially defined attributes that may be test specific, such as those that may be specifically chosen by the user for a specific purpose for a particular test.
In every test scenario, certain attributes are necessary to test which the user may not care about or is not interested in testing particular values that attribute. In such cases, as shown at block 115 , the built-in logic and rules of DAVSI automatically generate values for such attributes within ranges of values over which they vary. DAVSI further permits change at a later time, if the attributes and their values change. In a preferred embodiment, the DAVSI generated values of these attributes will be held as core attribute information, as it is unlikely that they need to be varied from one test to another.
The core versus changeable classification of attributes determines which attributes are tested more thoroughly. In a preferred embodiment, for example, testing of core attributes is conducted on a random basis as opposed to the changeable attributes that have to be tested one by one to ensure integrity of the computing environment.
Generally attributes and their associated values are determined and categorized based on a variety of factors and a combination of elements such as new design, timing of the test and even user input selection. In different embodiments of the present invention, a variety of ways are utilized to select attributes for test. In one embodiment, for example, users select the attributes themselves. In another embodiment, DAVSI selects attributes automatically by monitoring the workloads and resources of the computing environment. However, the sets of rules and logic that are built into DAVSI are designed in a way as to assist selection of test values in the most effective and creative ways. Based on the attribute categorization and values, DAVSI then generates computer readable instructions, as shown at 130 , to provide automated testing in the computer environment. In a preferred embodiment this task is accomplished through the generation of one or more job control commands. New job control commands are generated dynamically for changing values so that new test scenarios are created to address unanticipated situations on an “on-the-fly” basis, allowing test runs to proceed without needing to stop to gather information for further testing.
An overview illustrating the components of a test automation tool for providing DAVSI according to an embodiment of the invention is illustrated in FIG. 2 . As shown therein, the test automation tool includes a job submission engine (JSE) 210 , a job control file generator ( 220 ) for creating job control files (JCFs) 230 , and one or more agents 270 . The job submission engine (JSE) 210 is in charge of obtaining input from interfaces, such as user interfaces. These inputs are provided to the JCFG 220 which identifies and categorizes the attributes of the test and generates job control files based on the attributes for further testing. The job control files are then provided back to JSE for running the actual tests.
The job queuing system 250 is not a part of the test automation tool 200 , but rather, forms a part of the system under test, whether such system contains a single node or a cluster of nodes. The job queuing system is typically implemented by software which runs above the operating system level. The function of the job queuing system is to assign jobs to a node or nodes of the computing environment under test 240 , according to parameters of the job such as its priority, the number of nodes, etc., as submitted thereto by the JSE 210 .
The job queuing system 250 schedules execution of jobs including those in which existing test programs are executed. To this end, an application test pool 255 is provided, which contains a body of applications adapted to exercise various features of the system under test 240 . Such applications can be pre-installed on the nodes, or otherwise brought onto the system under test as needed for execution of a particular job.
Results of job execution are stored to a log file 260 . The log file 260 holds the necessary information rather than all common job control commands, with the added benefit of reducing its size dramatically. The information stored in the log file is also necessary for tracing back the value set for each attribute in each test case. This simplifies the debugging and problem isolating process.
In addition to the above-described elements, the agents 270 are provided for the purpose of analyzing job completion and/or error analysis. The purpose and operation of agents 270 will be described more fully below.
An example of such agent is a job results analysis (JRA) agent, as shown at 273 . JRA and a list of other availably used agents can be used to create specific test automation instructions and programs. For example, it maybe essential that any test automation tool have an error analysis agent as well. This is so that errors when happen with the automation method and tool itself can be monitored and the capability of tracing back jobs or application features can also be placed under control. To accomplish this task specific agents are used to analyzing certain aspects of the job results that have led to creation of errors or error like conditions. For example, all abnormal conditions may be registered as error while conditions arising out of job cancellations or intentional putting of jobs on hold, are not really error conditions and shall not be treated as such. In such an instance the analysis task is broken up into smaller agents to prevent all of the analysis into one big program or process. Usually users would monitor test results, but agents can be provided in similar ways to automate, or even semi-automate such tasks when desired.
The test automation tool makes use of an application test pool (ATP) as shown at 255 . This includes the actual applications or test programs for which JCFG 220 generates the job control file. For automating purposes, the applications are categorized into different groups. As mentioned earlier, some of the job command file attributes have different values for different groups of applications. In this way, the test automation tool accommodates jobs having special requirements so that different types of jobs can be incorporated into testing. The same ATP can be used in this way even in different configurations or releases. It is also easier to incorporate newly added features in such case.
Now that the components of the test automation tool have been introduced, the structure and operation of each component is now described. The JSE 210 is the focal point for job integration of the test automation tool. As shown in FIG. 3 , in an embodiment JSE 210 includes several components, namely an interface 340 to the job control file generator, a user interface 320 , and a job queuing system interface 330 which manages the submission of and running of test loops.
The interfaces 320 and 340 are provided to allow the selection of attributes, or input, either by communicating directly with the user or automatically by reference to pre-existing files, as will be described below. When input is not user selected, it is provided automatically by the test automation tool, such as by analyzing the computing environment and the level of testing to be performed as to particular attributes of the computing environment. Such analysis examines attributes that appear to affect testing of the environment in one way or another. Some of these attributes are illustratively depicted and represented in FIG. 3 . Frequency of job submission as a function of time (creating delays between running loops), shown at 311 ; job population as relating to job queues, shown at 312 ; error injection criteria, shown at 313 , including also other indirectly related eventualities such as number of jobs cancelled, as shown at 302 , number of jobs that are put on hold, as shown at 304 , are all examples of such attributes. Input can also be based on additional job activities such as favoring jobs and changing job priority, as shown at 306 and 305 , respectively, these being among those which can be provided by the user, for example. The maximum number of resources, shown at 315 , such as machines available for a particular test run and maximum job tasks running for each machine or resource, shown at 316 , and randomization of number of nodes and tasks per nodes, shown at 317 , are also available as input especially when multiple nodes are used. It should be noted that the list provided by FIG. 3 only serves an illustrative purpose and other input items may be added or removed from it. No matter how selected, the input provides the basis for attribute selection used in testing. From the attributes, values are generated and passed as parameters to help create testing scenarios that become the basis of JSE's running loops.
Depending on the number of jobs under test, a running loop may be simple and short or complex and long. Each of the parameters passed are ultimately used in creation of testing scenarios by the automated built-in factors of DAVSI for continuous testing. For example, input 311 relating to frequency of job submission is used to cause a delay time in between loops to control the pace of the test. However, since delay-free loop testing may create stress, input that adjusts the delay time can help set the pace of testing, and test for different levels of stress on the environment.
Similarly, input relating to job population values 312 can be used to generate tests that check degradation in the environment by adjusting the workload level. A sustained workload level throughout a test run can help detect signs of degradation on system performance at anytime during the test.
Input is also provided for establishing error injection criteria. Error injection is useful for creating abnormal conditions, as well as for recreating abnormal conditions that occur in other contexts. The manner that the computing environment or any component of it handles such abnormal conditions and the response or the computing environment in initiating recovery actions can be tested using error injection. Error injection can be used to mimic real-life problems and situations. Alternatively, some such scenarios do not rise to the level of a problem. For example, canceling jobs ( 302 ) and putting jobs on hold ( 304 ) may alter certain situations in the environment. Testing for such scenarios may help to identify defects sooner.
Additional job activities such as favoring certain jobs ( 306 ), and changing the priority of jobs ( 305 ) provide conditions that test effects of adding new features and/or workload to the computing environment. New features can usually be added to the workload as combinations of multiple purpose integrated testing. The effects are multiplied because these commands are queued up for the daemons to execute in the background while running applications in the computing environment. Normally, such tests have the effect of paralleling stresses at the same time on the daemons.
Input can also provide a test run that examines the number of available test nodes. A scenario testing the maximum number of nodes represented in a computing environment can result from the input as depicted by 315 . There are instances in real life where the number of nodes available for job processing are fixed. However, in dynamic environments, nodes are added and dropped from the environment. In testing environments, the number of available test machines or nodes on which the test can be performed is as stable as the node itself. Therefore, due to the nature of most parallel applications, it is important to know in advance the number of available test machines or nodes in order to set up the test run that can replicate maximum stress. Changing the number of nodes used by a parallel job can change the number of jobs running simultaneously in the environment.
The maximum number of job tasks per node, as shown at 316 , can also be varied according to input provided thereto. The maximum job tasks per node tends to stress the limits of available resources of the computing environment. These resources can include almost any computing component such as adapters, number of channels supported or even the number of windowed applications. These limits can vary significantly for different releases of different applications. Therefore, it is important to provide such input in order to test the limits of the computing environment when running in an environment that supports many nodes and configurations.
Input for randomizing the number of nodes 317 and number of tasks running on each node is another example. Here, in an embodiment, an experienced user is allowed to provide detailed input to select particular nodes in a quasi-random manner for testing based on the user's intuitive experience. Alternatively, the user may simply indicate a range of nodes or tasks per node to be particularly tested through random selection of particular values by the test automation tool.
While the JSE 210 collects input through interfaces and submits jobs for testing to a job queuing system of the computing environment, and monitors execution of the jobs, a set of job control files for submitting test jobs to be run on the computing environment are generated by the job control file generator (JCFG) 220 .
FIG. 4 is a flow diagram illustrating the functionality of JCFG 220 . JCFG 220 is the responsible component for categorizing of to be tested attributes after they are provided through the input from JSE 210 that ultimately lead to generation of job control files that provide the test runs.
In an embodiment of the present invention, specific “keywords” are used to identifying attributes and distinguish them as part of the different categories discussed earlier. For example, keywords can be used to search for all functionality and therefore associated parameters and differentiate those that require careful testing from others. In this way, environments that are unknown to the user can be automatically searched to determine the attributes thereof and provide for their testing, according to the keywords. This approach ensures that a user or even an automation program has not inadvertently missed a feature that should be tested.
This concept is depicted in detail in FIG. 4 . The generation of control files commences by categorization of JSE provided input in form of attributes. FIG. 4 provides for the organization of these attributes. As explored earlier, these attributes are deemed to be generic or core attributes 402 or dynamic attributes 404 or those relating to special job requirements 406 . JCFG 220 does not treat these attributes equally but handles according to that required to be accomplished and the special job requirements which may be provided by the user. The JCFG generates JCFs by setting values of the attributes for testing as constrained by the time and resources allotted for testing. While core attributes are always required to be tested somewhat to ensure to assure continued performance, changeable attributes capable of causing new and changed conditions of the computing environment require more thorough testing.
To locate core attributes correctly and categorize them as such, in a preferred embodiment, the concept of keyword use is extended to core attributes. In this case, the core attributes are keywords provided in a template file, shown at 410 . Each keyword is assigned a value, and JCFG reads the template file in creating job control files (JCFs), as shown at 450 . The job control file 450 can be changed as often as necessary in a dynamic environment such that there is a newly generated file every time a configuration is changed; or it can be created once and forgotten about depending on the level of testing required for these values. The JCFG 220 does not need to read the values to be tested from the template file. As described below, the user can specify the ranges of values for certain attributes over a user interface. Then, the JCFG 220 generates a random value for each of those attributes. Although random, the value is within the range of values that the user specifies.
Changeable, i.e. non-generic attributes are also identified and categorized as such by JCFG 220 . Such attributes, as discussed above, include dynamic attributes 404 and special job requirements 406 for execution. In an embodiment, a plurality of value setting methods 420 are provided and available for generating the values for creating JCFs for testing according to these attributes. These examples will be discussed in conjunction with illustrative depictions of FIG. 5 .
Such value setting methods include generating JCFs that exercise all values of an attribute over a range of values of that attribute. As shown at 610 in FIG. 5 , an attribute varies over a range of values. For example, if the attribute is the number of nodes in a cluster of nodes of the computing environment, and that number has changed from a prior configuration of 100 nodes to 110 nodes, the value setting method generates a series of JCFs to be performed in test iterations, each JCF testing according to a different number of nodes between 101 nodes and 110 nodes.
In an alternative embodiment, when the number of values of the attribute are smaller than the number of test iterations to be performed, some of the values are such that they will be exercised more often than other values during normal operation of the computing environment. In such case, the JCFG generates JCFs in which the number of times values are tested for that attribute are provided by a distribution of values 620 FIG. 5 ) according to a weighting or percentage that the value occurs or is expected to occur in normal operation.
In still another embodiment, when a value is to be randomly generated by the JCFG, an interface to the JCFG is provided for the user to specify the probability that a particular value or a value within a particular range of values will generated for a particular attribute. For example, when the attribute is “memory”, it can take one of two values: “shared” and “non-shared”. In such example, the user can specify a probability that a value of “shared” will be generated for about 90% of test cases, and a probability that a value of “non-shared” will be generated for about the other 10% of test cases.
According to yet another embodiment, the values of each attribute are selected randomly within the range of permitted values for the attribute, as shown at 630 in FIG. 5 . In the two previous examples of value setting methods, predictable variation of attribute values were considered. In this example, values are selected randomly, in a way that, hopefully, matches unpredictable patterns in which some attributes vary. In such case, values are selected based upon the output of a random number generator, for example. This method is applied particularly to situations in which there are too many values for an attribute to provide 100% test coverage, i.e. there are too many values to be able to test according to every value of that attribute.
Value setting methods other than those specifically described herein can be used in addition to or in conjunction with the ones discussed in relation to FIG. 5 . In a preferred embodiment of the present invention, once the test automation tool determines that a certain attribute should be categorized as dynamic, that categorization overrides other determinations for that attribute as may be provided elsewhere, such as in a template file having core attribute values.
Besides dynamic attributes, as discussed above, another type of changeable attributes are user-specified attributes including those referred to herein as special attributes or special job requirements. Determination of the values for testing according to user-specified attributes can be made with input from a user in relation to goals for testing to be performed in general, or alternatively, regarding testing to be performed for a specific run. In an embodiment, the user-specified attributes are stored in user input files that are referred to by the JCFG when creating JCFs for testing in accordance therewith.
With reference to FIG. 4 , the manner of handling user-specified attributes is as follows. As shown at 425 , the JCFG 220 reads the input file containing these attributes as a form of script. The job control file is then created as shown at 450 based on the script, although the script may include materials that fall outside of the job control file. Some examples reflecting the usages for such scripts are generating or copying input files; cleaning up of the temporary files for a particular job, especially between job runs; and passing data back to the JCFG. The latter operation, for example, may involve specifying the number of nodes that a particular JCF requires for performance and particular requirements for event processing.
In concluding a discussion about identification and selection of attributes and generation of the appropriate control files by JCFG 220 , a special mention should be made to some tests that may not fall under ordinary attribute categorizations as discussed earlier. The generation of test for these special and selection of appropriate attributes may be done in a manner that is more of an exception to the routines described above. One such case is that of regression testing. The attributes in a regression test, for example, are handled in a similar manner to core attributes in that they are placed in a template file. Regression test attributes may contain non-generic attributes. Nonetheless, because of the nature of the regression test, all such values should be treated essentially as core attributes. This is because regression test attributes are not to be the focus of rigorous testing due to time and resource constraints, even though they nevertheless must be included in all test runs. Regression testing has to be performed on all test runs because the introduction of some new features or function may affect existing ones. It is possible that pre-existing features and functions of the computing environment will not work properly with the added features. In a preferred embodiment, a core list of attributes is kept in a file at all times specifically for regression test purposes.
By contrast, a focus test scenario usually involves the testing of new features that need to be thoroughly tested for completeness, at least for the first time. Therefore, in a focus test, unlike regression testing, because the concentration is on new and required attributes, all attributes are treated as non-generic, including the ones that under normal circumstances might have been identified as core. It can even be that after the first test run is provided, the focus test values, after such implementation need to be further tuned for testing purposes. The methods provided for setting values for testing according to embodiments of the invention, especially as described above relative to FIG. 4 , provide the desired flexibility for performing testing according to the goals of such focus testing.
During testing of the system, it is likely that run-time problems will occur such as the failure of jobs to complete execution or their outright cancellation. Further, errors may occur during run-time which do not cause the job to fail or be cancelled, but nevertheless must be analyzed to determine the underlying problem. Conventionally, human operators perform the isolation of and causes of run-time failures and errors. This is done by the operator poring over reams of output logs in a very tedious and time-consuming process which requires high analytical and debugging skills, as well as a thorough understanding of the applications, and characteristics of the particular system and its performance.
In an embodiment of the invention, agents are provided which avoid the human operator from having to do most of the legwork in identifying errors and job failures, and much of the work to analyze run-time problems such as cancellation of jobs and/or analysis of errors. In a particular embodiment, the test automation tool also includes one or more agents 270 for the purpose of analyzing results of run-time problems such as cancellation of jobs and/or analysis of errors. For example, a job cancellation agent determines why a particular job fails to execute at run-time, and is cancelled instead. The job cancellation agent is used to research job logs and identify jobs that were cancelled. The agent saves a list of job identifiers, which specify a list of cancelled jobs.
An error analysis agent is desirably provided as a semi-automated agent that determines the types of errors and traces them back to the failing jobs. The error analysis agent identifies failed jobs by reviewing the list of job identifiers. An alert is then issued upon occurrence of an error. The agent or a human operator can then exclude jobs that were cancelled on purpose, in order to isolate true job failures when they occur. Alternatively, the error analysis agent scans log files 260 to determine the presence of errors. When it appears that an error has occurred, the error analysis agent runs through one or more troubleshooting algorithms in which various conditions in the system leading up to the error are checked against a set of predetermined comparison conditions. In such manner, troubleshooting is conducted by the agent to determine the presence of and type of error that has occurred, as depends upon the series of comparisons between system conditions and the comparison conditions.
As described herein, ease of test automation and flexibility of testing are provided by embodiments of the invention, while preserving thorough testing within the time and resource constraints allotted thereto. Embodiments of the invention are useful in a variety of computing environments, from the simple to the complex. Not only are the test automation tools described herein adapted for use in many different computing environments, but human operator needs not have full in-depth knowledge of the computing environment under test, either before or during the test cycle. The particular ability of the test automation system to analyze and categorize system attributes based on keywords or methodology is important in this respect. A test designer or test operator assigned to test a system belonging to a specific customer might only be provided selective information about the customer's system environment, other information being kept confidential.
In prior art test systems, less than full knowledge of the system under test would lead to generation of test scenarios that were inadequate to test all necessary functions of the system. Test tools were designed beforehand and could not be changed if a new setup was encountered. Running jobs had to be stopped to make changes to the setup, as well to accommodate the automation tool. Alteration of the setup and disturbance to running jobs in customer settings were undesirable to customers. The automated categorization of attributes according to embodiments of the invention allow customer applications to be integrated into a pool of applications used for testing without requiring particular knowledge of the environment, or needing to change the setup or disturb jobs which are running.
While the invention has been described in detail herein in accord with certain preferred embodiments thereof, many modifications and changes therein may be effected by those skilled in the art. Accordingly, it is intended by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the invention.
|
A test automation tool is provided which is operable to integrate a set of dynamic attributes and values into tests to be performed on a computing environment. The test automation tool includes a job submission engine (JSE) operable to receive input regarding first attributes unchanged from a first computing environment and second attributes representing change from the first computing environment. A job control file generator (JCFG) is provided in electronic communication with the job submission engine and is operable to automatically generate job control files (JCFs) for controlling testing of the computing environment according to attribute values including first attribute values and second attribute values. First attribute values are generated based on an automatic sampling of values of first attributes. The JSE is further operable to automatically submit the JCFs to the computing environment for execution and to automatically monitor execution according to the JCFs.
| 6
|
This is a division of application Ser. No. 475,858, filed June 3, 1974, now U.S. Pat. No. 3,904,758.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to methods and compositions for controlling the central nervous system of humans or animals. More particularly, the invention relates to methods and compositions for temporarily alleviating the symptoms of hypersomnia or mental fatigue or drowsiness or suppressing appetite or for potentiating the effects of anti-depressant drugs.
2. Background of the Prior Art
Piperoxan or 2-piperidinomethyl-1,4-benzodioxan is a chemical compound having the following structural formula ##SPC1##
And is described in detail in U.S. Pat. No. 2,056,046. It has been used as an adrenergic blocking agent and in a diagnostic test for pheochromocytoma.
Mental fatigue or drowsiness are commonly observed in humans and animals. Drowsiness takes a form in hypersomnia, a term used generally to describe excessive sleeping. Further, persons suffering from depression have a tendency to sleep excessively. While various stimulants such as amphetamines have been used to treat some of the foregoing as well as suppress appetite, amphetamines have undesirable side-effects associated with their actions. Thus, it would be desirable to have available a compound which would act to temporarily overcome drowsiness or mental fatigue or hypersomnia or to suppress appetite without manifesting undesirable amphetamine-like side effects.
SUMMARY OF THE INVENTION
It has now been discovered that drowsiness or mental fatigue or hypersomnia may be temporarily overcome with the introduction of undesirable amphetamine-like side effects by the application of the methods disclosed and claimed herein.
The present invention relates to a method of temporarily alleviating symptoms of hypersomnia by administering to a person suffering from hypersomnia a composition comprising an effective amount of piperoxan or a pharmaceutically acceptable salt thereof together with a suitable pharmaceutical carrier.
The present invention also relates to a method of temporarily alleviating the symptoms of drowsiness or mental fatigue in humans by administering to a drowsy or mentally fatigued human a composition comprising an effective amount of piperoxan or a pharmaceutically acceptable salt thereof together with a suitable pharmaceutical carrier.
The present invention also relates to a method of potentiating the effects of anti-depressant drugs, that is, drugs for the treatment of mental depression, by administering to a depressed person about 20 to about 50% of a conventional effective dose of an anti-depressant drug in combination with, or concurrently with, a potentiating amount of piperoxan or a pharmaceutically acceptable salt thereof.
The present invention also relates to a composition comprising about 20 to about 50% of a conventional effective dose of an anti-depressant drug, a potentiating amount of piperoxan or a pharmaceutically acceptable salt thereof and a suitable pharmaceutical carrier.
The present invention also relates to a method for temporarily suppressing appetite in humans by administering to a human a composition comprising an effective amount of piperoxan or a pharmaceutically acceptable salt thereof together with a suitable pharmaceutical carrier.
DETAILED DESCRIPTION OF THE INVENTION
Piperoxan and its pharmaceutically acceptable salts may be made by the method described in U.S. Pat. No. 2,056,046, applicable portions of which are hereby incorporated by this reference. Pharmaceutically acceptable salts include conventional acid salts such as, for example, the alkali metal, alkaline earth metal, ammonium and organic amine salts of carboxylic acids and acid addition salts of the basic compounds formed with mineral acids, e.g. hydrochloric, sulfuric, nitric, phosphoric, etc. or with organic acids, e.g. acetic, maleic, etc.
The therapeutic amount of piperoxan which may be used in the present invention ranges from about 0.05 to about 50 mg/Kg and preferably from about 0.5 to about 25 mg/Kg.
Anti-depressant drugs which may be used in the present invention include monoamine oxidase inhibitors such as, for example, isocarboxazide, nialamide, phenelzine and tranylcypromine; and tricyclics such as, for example, imipramine, amitriptyline, desmethylimipramine (desipromine), desmethylamitriptyline and protriptyline.
While applicant does not necessarily rely on the following theory of action as to why piperoxan potentiates the effects of anti-depressant drugs, applicant subscribes to the theory that known anti-depressant drugs such as monoamine oxidase inhibitors or noradrenaline uptake inhibitors act by increasing noradrenaline receptor activity in the central nervous system. However, whenever the noradrenaline receptor activity is increased, compensatory mechanisms are initiated by the central nervous system to restore normal receptor activity. Applicant believes piperoxan acts by interfering with these compensatory mechanisms and thereby potentiates the effect of anti-depressant drugs by maintaining the higher noradrenaline receptor activity initially caused by the anti-depressant drug. In this manner, piperoxan can be used to potentiate the effects of anti-depressant drugs.
Further, piperoxan, when administered in combination with, or concurrently with, an anti-depressant drug, allows the use of lower doses, that is, 2-5 times less, anti-depressant drug to obtain the same effect as obtained with higher doses of an anti-depressant drug without piperoxan. This is a valuable result as most anti-depressant drugs have various side effects, such as cardiotoxicity and anti-cholinergic actions, which are reduced as the dose is decreased. For example, the recommended dose for the anti-depressant imipramine hydrochloride ("Tofranil") is about 25-50 mg orally 4 times a day. When given in combination with or concurrently with piperoxan as described, the dose range for the anti-depressant imipramine hydrochloride may be reduced 2-5 times, i.e. reduced from a range of about 100-200 mg daily to about 20-100 mg daily, thereby reducing the chances for undesirable side effects caused by high doses of drug, while maintaining the effectiveness of the drug.
The pharmaceutical composition containing piperoxan or containing piperoxan together with an anti-depressant drug may be in a form suitable for oral use, for example, as tablets, aqueous or oily suspensions, dispersible powders or granules, emulsions, hard or soft capsules, or syrups or elixirs. Compositions intended for oral use may be prepared according to any method known to the art for the manufacture of pharmaceutical compositions and such compositions may contain one or more agents selected from the group consisting of sweeetening agents, flavoring agents, coloring agents and preserving agents in order to provide a pharmaceutically elegant and palatable preparation. Tablets contain the active ingredient in admixture with nontoxic pharmaceutically acceptable excipients which are suitable for manufacture of tablets. These excipients may be, for example, inert diluents, for example calcium carbonate, sodium carbonate, lactose, calcium phosphate or sodium phosphate; granulating and disintegrating agents, for example maize starch, or alginic acid; binding agents, for example starch, gelatine or acacia, and lubricating agents, for example magnesium stearate or stearic acid. The tablets may be uncoated or they may be coated by known techniques to delay disintegration and absorption in the gastrointestinal tract and thereby provide a sustained action over a longer period.
Formulations for oral use may also be presented as hard gelatine capsules wherein the active ingredient is mixed with an inert solid diluent, for example calcium carbonate, calcium phosphate or kaolin, or as soft gelatine capsules wherein the active ingredient is mixed with an oil medium, for example arachis oil, liquid paraffin or olive oil.
Aqueous suspensions contain the active ingredients in admixture with excipients suitable for the manufacture of aqueous suspensions. Such excipients are suspending agents, for example sodium carboxymethyl cellulose, methylcellulose, hydroxypropylmethylcellulose, sodium alginate, polyvinylpyrrolidone, gum tragacanth and gum acacia; dispersing or wetting agents may be a naturally-occurring phosphatide, for example lecithin, or condensation products of an alkylene oxide with fatty acids, for example polyoxyethylene stearate, or condensation products of ethylene oxide with long chain aliphatic alcohols, for example heptadecaethyleneoxycetanol, or condensation products of ethylene oxide with partial esters derived from fatty acids and a hexitol, for example polyoxyethylene sorbitol monooleate, or condensation product of ethylene oxide with partial esters derived from fatty acids and hexitol anhydrides, for example polyoxyethylene sorbitol monooleate. The said aqueous suspensions may also contain one or more preservatives, for example ethyl, or n-propyl, p-hydroxy benzoate, one or more coloring agents, one or more flavoring agents and one or more sweetening agents, such as sucrose, saccharin, or sodium or calcium cyclamate.
Dispersible powders and granules suitable for preparation of an aqueous suspension by the addition of water provide the active ingredient in admixture with a dispersing or wetting agent, suspending agent and one or more preservatives. Suitable dispersing or wetting agents and suspending agents are exemplified by those already mentioned above. Additional excipients, for example, sweetening, flavoring and coloring agents, may also be present.
Syrups and elixirs may be formulated with sweetening agents, for example glycerol, sorbitol or sucrose. Such formulations may also contain a demulcent, a preservative and flavoring and coloring agents. The pharmaceutical compositions may be in the form of a sterile injection preparation, for example as a sterile injectable aqueous suspension. This suspension may be formulated according to the known art using those suitable dispersing or wetting agents and suspending agents which have been mentioned above. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example as a solution in 1,3-butane diol.
The pharmaceutical compositions containing piperoxan or containing piperoxan together with an anti-depressant drug may be tabulated or otherwise formulated so that for every 100 parts by weight of the composition there are present between 5 and 95 parts by weight of the active ingredient or ingredients and preferably between 25 and 85 parts by weight of the active ingredient or ingredients. A preferred dosage rate for oral administration is of the order of 1-1,000 mg daily, optionally in divided doses.
From the foregoing formulation discussion, it is apparent that the compositions of this invention can be administered orally or parenterally. The term parenteral as used herein includes subcutaneous injection, intravenous, intramuscular, or intrasternal injection or infusion techniques.
This invention is further demonstrated by the following examples in which all parts are by weight.
EXAMPLE I
Male Sprague-Dawley rats (250 g) were operated upon in a stereotaxic instrument under halothane oxygen anesthesia two weeks before the starting of the EEG recordings. Four electrodes for cortical EEG recordings and two for EMG recordings were implanted by drilling small holes in the skull above the frontal and parietal cortex and inserting four female connecting pins and three screws. Two electrodes were placed in the neck muscle and connected to two female pins held in a position behind the cortical electrodes. The set-up was fixed to the skull with dental cement. The EEG records were distinguished into four different stages of activity: "waking," cortical low voltage fast activity and a high muscle tone; "slow wave sleep 1," low voltage fast activity interrupted by high amplitude slow waves and a moderate to high EMG activity; "slow wave sleep 2," continued high voltage slow waves and a marked decrease of muscle tone; "paradoxical sleep", a waking EEG with a complete disappearance of EMG activity except for some twitches. Each minute of the record was scored as belonging to one of these four stages.
The results are shown in Table 1. Piperoxan in a dose of 5 mg/kg produces a significant increase in waking by about 30 percent. The other stages of sleep are not significantly changed.
Table 1
The effect of piperoxan on sleep and waking in the rat
The EEG recording started at 9 a.m. immediately after the piperoxan (5 mg/kg, i.p.) or saline injection and lasted for 6 hr. Each animal was used for 4- 5 days. The first day saline was used, followed by drug on the second day. This schedule was then repeated. The values for sleep and waking are expressed as percent of total time. Six animals have been used. n = number of 6 hr. recordings.
______________________________________Treat- Slow Wave Slow Wave Paradoxicalment n Waking Sleep 1 Sleep 2 Sleep______________________________________Saline 12 19.5 ± 1.6 14.1 ± 1.7 50.5 ± 2.0 15.3 ± 0.7Piper- 11 26.0 ± 1.6.sup.a 11.6 ± 1.7 48.5 ± 2.5 13.6 ± 0.7oxan______________________________________ .sup.a p<0.01 (Student's t-test)
EXAMPLE II
A mixture of 250 parts of piperoxan and 25 parts of lactose is granulated with suitable water and to this is added 100 parts of maize starch. The mass is passed through a 16-mesh screen. The granules are dried at a temperature below 60° C. The dry granules are passed through a 16-mesh screen and mixed with 3.8 parts of magnesium stearate. They are then compressed into tablets suitable for oral administration according to the method of this invention.
EXAMPLE III
A mixture of 50 parts of piperoxan, 3 parts of the calcium salt of lignin sulfonic acid, and 237 parts of water is ball-milled until the size of substantially all the particles of piperoxan is less than 10 microns. The suspension is diluted with a solution containing 3 parts of sodium carboxymethylcellulose and 0.9 part of the butyl ester of p-hydroxybenzoic acid in 300 parts of water. There is thus obtained an aqueous suspension suitable for oral administration for therapeutic purposes.
EXAMPLE IV
A mixture of 250 parts of piperoxan, 50 parts imipramine hydrochloride, 200 parts of maize starch and 30 parts of alginic acid is mixed with a sufficient quantity of a 10% aqueous paste of maize starch and granulated. The granules are dried in a current of warm air and the dry granules are then passed through a 16-mesh screen, mixed with 6 parts of magnesium stearate and compressed into tablet form to obtain tablets suitable for oral administration.
EXAMPLE V
A mixture of 500 parts of piperoxan, 60 parts of maize starch and 20 parts of gum acacia is granulated with a sufficient quantity of water. The mass is passed through a 12-mesh screen and the granules are dried in a current of warm air. The dry granules are passed through a 16-mesh screen, mixed with 5 parts of magnesium stearate and compressed into tablet form suitable for oral administration.
|
Methods of temporarily alleviating symptoms of hypersomnia or mental fatigue or drowsiness or temporarily suppressing appetite by administering to a human or animal having one or more of the aforementioned symptoms an effective amount of piperoxan together with a suitable pharmaceutical carrier. Piperoxan is also useful for potentiating the effects of anti-depressant drugs.
| 0
|
BACKGROUND
[0001] The present disclosure relates generally to medical devices and, more particularly, to sensors used for sensing physiological parameters of a patient.
[0002] This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.
[0003] In the field of medicine, doctors often desire to monitor certain physiological characteristics of their patients. Accordingly, a wide variety of devices and techniques have been developed for monitoring physiological characteristics. Such devices and techniques provide doctors and other healthcare personnel with the information they need to provide the best possible healthcare for their patients. As a result, these monitoring devices and techniques have become an indispensable part of modern medicine.
[0004] One such monitoring technique is commonly referred to as pulse oximetry. Pulse oximetry may be used to measure various blood flow characteristics, such as the blood-oxygen saturation of hemoglobin in arterial blood and/or the rate of blood pulsations corresponding to each heartbeat of a patient.
[0005] The devices based upon pulse oximetry techniques are commonly referred to as pulse oximeters. Pulse oximeters typically utilize a non-invasive sensor that is placed on or against a patient's tissue that is well perfused with blood, such as a patient's finger; toe, forehead or earlobe. The pulse oximeter sensor emits light and photoelectrically senses the absorption and/or scattering of the light after passage through the perfused tissue. A photo-plethysmographic waveform, which corresponds to the cyclic attenuation of optical energy through the patient's tissue, may be generated from the detected light. Additionally, one or more physiological characteristics may be calculated based upon the amount of light absorbed or scattered. More specifically, the light passed through the tissue may be selected to be of one or more wavelengths that may be absorbed or scattered by the blood in an amount correlative to the amount of a blood constituent, such as oxygen or oxyhemaglobin, present in the blood. The amount of light absorbed and/or scattered may then be used to estimate the amount of oxygen in the tissue using various algorithms.
[0006] For example, a reflectance-type sensor placed on a patient's forehead may emit light into the skin and detect the light that is “reflected” back after being transmitted through the forehead tissue. A transmission-type sensor may be placed on a finger, wherein the light waves are emitted through and detected on the opposite side of a finger. In either case, the amount of light detected may provide information that corresponds to valuable physiological patient data. The data collected by the sensor may be used to calculate one or more of the above physiological characteristics based upon the absorption or scattering of the light. For instance, the emitted light is typically selected to be of one or more wavelengths that are absorbed or scattered in an amount related to the presence of oxygenated versus de-oxygenated hemoglobin in the blood. The amount of light absorbed and/or scattered may be used to estimate the amount of the oxygen in the tissue using various algorithms.
[0007] The sensors generally include an emitter that emits the light and a detector that detects the light. The emitter and detector may be located on a flexible circuit that allows the sensor to conform to the appropriate site on the patient's skin, thereby making the procedure more comfortable for a patient. During use, the emitter and detector may be held against the patient's skin to facilitate the light being directed into and received from the skin of the patient. For example, a sensor may be clipped about a patient's finger tip with the emitter placed against the finger nail, and the detector placed against the under side of the finger tip. When fitted to the patient, the emitted light may travel directly through the tissue of the finger and be detected without additional light being introduced or the emitted light being scattered.
[0008] However, in practice, the shape and design of the sensor may be uncomfortable to the patient. Discomfort may be caused by shielding and protection provided on the optical devices, i.e. the photodetector and the emitter. For example, the detector and emitter may include materials or layers to protect measurement signals from being affected by external static electrical fields or external light. These materials can add to the bulkiness of the sensor. Further, after repeated use, the materials and layers may separate or delaminate, causing additional discomfort and resulting in potential erroneous measurements. Moreover, manufacturing the sensor, the optical devices and the protective layers may be a tedious and time consuming activity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Advantages of the disclosure may become apparent upon reading the following detailed description and upon reference to the drawings in which:
[0010] FIG. 1 illustrates a patient monitoring system coupled to a multi-parameter patient monitor and a sensor assembly including a photodetector, in accordance with an embodiment;
[0011] FIG. 2 is a perspective view of a clip style embodiment of the sensor assembly shown in FIG. 1 , in accordance with an embodiment, mounted in the hat;
[0012] FIG. 3 is a perspective view of the sensor assembly shown in FIG. 1 placed on a patient's finger, in accordance with an embodiment;
[0013] FIG. 4 is a side view of the sensor assembly shown in FIG. 1 , including a photodetector and an emitter, in accordance with an embodiment;
[0014] FIG. 5 illustrates a view of a bandage style embodiment of the sensor assembly, in accordance with an embodiment;
[0015] FIG. 6A-6C are views of the photodetector assembly shown in FIGS. 1-5 , shown prior to application of overmolds, in accordance with an embodiment;
[0016] FIG. 7A-7C are views of the photodetector assembly shown in FIGS. 1-5 , shown after the application of a nonconductive transparent overmold, in accordance with an embodiment; and
[0017] FIGS. 8A-8C are views of the photodetector assembly shown in FIGS. 1-5 , shown after the application of a nonconductive transparent overmold and a conductive overmold, in accordance with an embodiment.
DETAILED DESCRIPTION
[0018] One or more specific embodiments of the present disclosure will be described below. In an effort to provide a concise description of these embodiments, not all features of an actual implementation are described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
[0019] As described herein, various embodiments of sensors are provided featuring various coatings to prevent shunting and interference from external light as well as external static forces. Further the embodiments of sensors discussed are designed to fit a range of patient application areas and are designed to provide a simplified method for manufacturing. In general, embodiments of the sensors include optical components (e.g., emitters and detectors) that are coated with a material that blocks the passage of light from external sources as well as directly between the emitter and detector. In certain embodiments, one or more of the optical components may also be coated with a material that prevents or reduces electrical interference,
[0020] Prior to discussing examples of such sensor assemblies in detail, it should be appreciated that such sensors may be typically designed for use with a patient monitoring system. For example, referring now to FIG. 1 , sensor 10 may be used in conjunction with patient monitor 12 . Sensor 10 , as depicted in FIG. 1 , is designed to be placed on a patient's finger. In the depicted embodiment, cable 14 connects sensor 10 to patient monitor 12 . Sensor 10 and/or cable 14 may include or incorporate one or more integrated circuit or electrical devices, such as a memory processor chip, that may facilitate or enhance communication between sensor 10 and patient monitor 12 . Similarly, cable 14 may be an adaptor cable, with or without an integrated circuit or electrical device, for facilitating communication between sensor 10 and various types of monitors, including different versions of patient monitor 12 or other physiological monitors. In other embodiments, sensor 10 and patient monitor 12 may communicate via wireless means such as using radio frequency, infrared, or optical signals. In such embodiments, a transmission device may be connected to sensor 10 to facilitate wireless transmission between sensor 10 and patient monitor 12 . As will be appreciated by those of ordinary skill in the art, cable 14 (or a corresponding wireless connection) may be used to transmit control or timing signals from patient monitor 12 to sensor 10 and/or to transmit acquired data from sensor 10 to patient monitor 12 .
[0021] In one embodiment, patient monitor 12 may be a suitable pulse oximeter, such as those available from Nellcor Puritan Bennett L.L.C. In other embodiments, patient monitor 12 may be a monitor suitable for measuring tissue water fractions, or other body fluid related metrics, using spectrophotometric or other techniques. Furthermore, patient monitor 12 may be a multipurpose monitor suitable for performing pulse oximetry and measurement of tissue water fraction, or other combinations of physiological and/or biochemical monitoring processes, using data acquired via the sensor 10 and/or other sensors. Moreover, to upgrade conventional monitoring functions provided by the system, patient monitor 12 may be coupled to a multi-parameter patient monitor 16 via cable 18 connected to a sensor input port and/or a cable connected to a digital communication port.
[0022] In an embodiment, the sensor 10 , as depicted in FIG. 1 , may be a clip-style sensor assembly. In such an embodiment, the clip-style sensor may utilize transmission spectrophotometric techniques to monitor one or more parameters. In other embodiments, the sensor 10 may be a reflectance type sensor assembly using reflectance spectrophotometric techniques. The sensor 10 may include optical components, such as detector 22 and emitter 24 , which may be of any suitable type. For example, in one embodiment the emitter 24 may be one or more light emitting diodes adapted to transmit one or more wavelengths of light, such as in the red to infrared range, and the detector 22 may be a photodetector, such as a silicon photodiode package, selected to receive light in the range emitted from the emitter 24 . In the present context, detector 22 may be referred to as a photodetector, a detector device, a detector assembly or a detector component. Further, detector 22 and emitter 24 may be referred to as optical components or devices.
[0023] In the depicted embodiment, the sensor 10 is coupled to a cable 14 that is responsible for transmitting electrical and/or optical signals to and from the emitter 24 and the detector 22 of the sensor 10 . The cable 14 may be permanently coupled to the sensor 10 , or it may be removably coupled to the sensor 10 —the latter alternative being more useful and cost efficient in situations where the sensor 10 is disposable. In an embodiment where sensor 10 is disposable, the unitary assemblies of emitter 24 and detector 22 as described herein may allow them to be easily removed from the sensor body, which may be disposed of after use on a patient. The emitter 24 and detector 22 may then be cleaned and placed in a new sensor body for use on a new patient.
[0024] Turning now to FIG. 2 , a perspective view of a clip-style embodiment of sensor 10 is shown, according to an embodiment. The assembly of sensor 10 includes an upper clip portion 26 and a lower clip portion 28 . As depicted, upper clip portion 26 includes a housing 30 that features a cavity for detector 22 , while the lower clip portion 28 includes a cavity for emitter 24 . In other embodiments the emitter 24 and detector 26 may be reversed. Further, housing 30 may be configured to allow detector 22 to be removed either through the outer portion of housing 30 or the skin contacting portion of upper clip portion 26 . As depicted, the sensor assembly 10 may allow the optical devices to be easily removed for cleaning of the sensor body and the devices. Further, the components and/or sensor body may be covered with an overmold that would facilitate cleaning, such as by rinsing off the device or body with water or a solution.
[0025] FIG. 3 shows the clip-style embodiment of sensor assembly 10 in operation. As depicted, upper clip portion 26 and lower clip portion 28 have been separated, allowing a patient's finger 34 to be inserted in the clip-style sensor assembly 10 . In one embodiment, light waves may be emitted by emitter 24 into the bottom of patient finger 34 . The light waves may then be transmitted through the patient's finger tissue and received by detector 22 . A signal corresponding to the detected light waves may be sent to the patient monitor via cable 14 . In one embodiment, the skin contacting components of sensor assembly 10 may be formed to be as comfortable as possible so as not to irritate the skin while the sensor is on a patient's finger. Therefore, utilizing suitable materials for sensor assembly 10 improves overall comfort and performance of clip style sensor assembly 10 .
[0026] With the foregoing discussion in mind and turning now to FIG. 4 , a cut-away side view of a clip-style embodiment of sensor assembly 10 is illustrated. In one embodiment, detector device 22 may be located on the skin contacting side of upper clip portion 26 . Similarly, emitter device 24 may be located on the skin contacting side of lower clip portion 28 . Signals may be routed to or from the optical devices by component lead wires 36 which may be bundled into cable 14 . Detector device 22 and emitter device 24 may each include or be proximate to a transparent window which allows light to be transmitted between the optical components via light transmission path 38 , which may pass through a patient's finger tissue.
[0027] In other embodiments, the sensor may not be a clip-style sensor. For example, turning now to FIG. 5 , an embodiment of a bandage style sensor 40 is illustrated. The bandage style sensor 40 may be applied to any well perfused area of a patient, such as a patient's forehead. As depicted, the bandage style sensor 40 may include optical devices photodetector 22 and emitter 24 . In one embodiment, the optical devices each feature windows that allow light to be transmitted to and received from the patient's tissue. In one embodiment, signals may be transmitted to and from the optical devices by lead wires 36 . In the depicted embodiment, lead wires 36 route signals to the monitor via cable 14 . In one embodiment, the bandage style sensor 40 may use an adhesive layer to attach the sensor 40 to the patient's skin. The adhesive layer may include an acrylic or synthetic rubber adhesive or other suitable adhesives. Alternatively, in another embodiment, the bandage style sensor 40 may be applied without adhesive, instead being made from a foam PVC or foam polyurethane material and attached to the skin by medical tape.
[0028] With the foregoing discussion of various sensor and optical component assemblies in mind, FIGS. 6A through 8C show embodiments of a photodetector assembly for use in accordance with the present disclosure. In particular, FIGS. 6A through 8C show various stages of one embodiment of a manufacturing process for the photodetector assembly. FIGS. 6A-6C show perspective, front and side views of the photodetector assembly prior to the application of overmold materials. In the depicted embodiment, the photodetector assembly includes detector face 42 , lead frame 44 , and ground lead 46 . In one embodiment, detector face 42 receives light waves that are converted into electrical signals which are transmitted to an associated patient monitor via lead frame 44 and attached cables. FIG. 7A-7C illustrates the photodetector assembly after the application of an overmold material, in accordance with an embodiment. For example, in one such embodiment, the photodetector assembly includes transparent non-conductive overmold 48 disposed about detector face 42 and a portion of lead frame 44 . In the depicted embodiment, the transparent non-conductive overmold 48 includes a protruding window 50 . In one such embodiment, window 50 is located in front of detector face 42 , thereby permitting light to be received by the detector face 42 through the window 50 .
[0029] FIGS. 8A-8C show perspective, front and side views of a photodetector assembly after the application of transparent non-conductive overmold 48 and conductive overmold 52 , in accordance with an embodiment. In one embodiment, the conductive overmold 52 may cover a portion of lead frame 44 and transparent non-conductive overmold 48 . In the depicted embodiment, conductive overmold 52 does not cover window 50 which allows detector face 42 to receive incoming light waves. Further, in the depicted embodiment, conductive overmold 52 is approximately the same thickness as the protrusion of window 50 , meaning that the surface of conductive overmold 52 is flush with the surface of window 50 . In one embodiment, ground lead 46 is in contact with conductive overmold 52 , enabling the conductive overmold 52 to be connected via cable to a ground located on a monitor.
[0030] In one embodiment, a substantial portion of the photodetector assembly is shielded from electromagnetic and static fields by conductive overmold 52 , which serves as a Faraday shield for the optical device. In one such embodiment, transparent non-conductive overmold 48 insulates detector face 42 and other assembly components from electrical contact with conductive overmold 52 . Transparent non-conductive overmold 48 and conductive overmold 52 may be composed of any suitable material, such as neoprene, silicone, plastic, polyurethane, polypropylene, nylon, urethane, epoxy, and/or other suitable materials. Moreover, different materials or combinations of materials may be used for each of the overmolds. For instance, in one embodiment, the conductive overmold 52 may be composed of a medical grade silicone, epoxy, and/or polypropylene containing a conductive additive, such as metal fibers, carbon fibers, carbon powders or carbon nanotubes. In one embodiment, conductive overmold 52 may be completely or partially opaque, however, in other embodiments, conductive overmold 52 is not opaque.
[0031] In one embodiment, the optical component and associated overmold layers constitute an assembly that may be inserted and removed from the sensor body. For example, in one embodiment, a photodetector assembly, as shown in FIGS. 6A-8C , may be utilized in a suitable pulse oximetry sensor, including the bandage-style sensor of FIG. 5 or the clip-style sensor of FIGS. 1-4 . In addition, the arrangement of the overmold layers in such an embodiment protects the photodetector device from contaminants and other debris by providing a hermetic seal about the components.
[0032] In certain embodiments, the use of overmolded optical components also allows a simplified approach to cleaning and replacing the optical components within a sensor assembly. For example, in one embodiment the photodetector assembly may be removed as an integral unit from a housing or frame of a clip style sensor by application of a mechanical force to overcome a force that may be exerted by the housing to keep the assembly in place. As described herein, in certain embodiments the photodetector assembly may include a cable connected to the lead frame 44 and covered in a rubber casing, which, along with the overmolds, provide protection for the entire detector assembly. In one such embodiment, the rubber casing and overmold allow the assembly to be easily cleaned with water or a solution. After removal of such an overmolded detector assembly, the housing may also be easily cleaned. Similarly, the easy removal and insertion of the detector assembly allows for simplified replacement of the device in the sensor housing.
[0033] The application of transparent nonconductive overmold 48 and/or conductive overmold 52 to the optical components, such as the photodetector, may be accomplished by any suitable means. For example, in one embodiment, a detector assembly may be formed by an injection molding process. In one example of such a process the lead frame 44 and detector 22 may be positioned within a die or mold of the desired shape for the assembly. A molten or otherwise unset overmold material may then be injected into the die or mold. For example, in one implementation, a molten thermoplastic elastomer at between about 400° F. to about 450° F. is injected into the mold. The overmold material may then be set, such as by cooling for one or more minutes or by chemical treatment, to form the overmold layer about the lead frame 44 and detector 22 . Further, the application of an overmold, as described herein, may be applied to any suitable electronic component, including LEDs and photodiodes.
[0034] The configuration, thickness, and number of overmold layers may vary depending upon several factors including size and weight constraints as well as costs, materials used, manufacturing limitations and environment. In one embodiment, the use of one or two overmold layers may reduce the complexity of the detector assembly, thereby reducing overall size and bulkiness of the photodetector assembly. For example, the use of conductive overmolding instead of metallic mesh for the device's Faraday shield may be more compact, resist separation/delamination and eliminate a source of discomfort for the patient. In other embodiments, additional overmold layers, such as an addition nonconductive overmold layer may be utilized. Further, the simplified approach to shielding the photodetector may increase robustness of the photodetector and sensor assembly by providing an overmolded material that will resist delamination or degradation after repeated use. Moreover, the assembly may allow for easy removal of the unitary optical device, thereby enabling the device to be removed and replaced for cleaning or maintenance. The arrangement also allows for a simplified manufacturing process for the optical device, thereby reducing costs and complexity of the sensor assembly.
[0035] While the disclosure may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the disclosure is not intended to be limited to the particular forms provided. Rather, the disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the following appended claims. Indeed, the present disclosed methods may not only be applied to transmission type sensors for use in pulse oximetry, but also to other sensor designs. Likewise, the present disclosure is not limited to use on ears, digits, or foreheads but may also be applied to placement on other body parts.
|
Embodiments described herein may include devices and methods of manufacturing devices for sensing and monitoring physiological parameters of a patient. Specifically, certain embodiments disclose the use of conductive and nonconductive overmold materials to protect the device, increase reliability, increase comfort, and increase accuracy of the parameters measured.
| 0
|
BACKGROUND OF THE INVENTION
The invention relates to foldable ladders of the type which are folded for storage in the event of an emergency at which time they can be unfolded and used to escape from an elevated structure. These ladders are often used as emergency fire escape means and may be secured in a container outside a window, for immediate use. Similar, though shorter ladders, are often used in boats to permit ease of returning into the boat from, for example, the water.
Foldable ladders are well known and have been in use for many years. An extremely old and very common type of foldable ladder is a so-called rope ladder. These usually comprise a series of elongated rigid steps maintained approximately parallel to each other by two ropes, one secured to each end of the steps. The rope permits rolling the ladders into a cylindrical bundle.
The main disadvantage of the known foldable ladders resides in their lack of apparent stability. As these ladders may find utilization as emergency exits, persons not used to climbing ladders may find themselves in a position when they must use a folding ladder in an emergency. If the ladder feels insecure, one often encounters difficulty in using a ladder for the first time. If the person is at all acrophobic, the use of prior art type foldable ladders can be devastating, if not fatal.
In an endeavor to avoid the deficiencies of the prior art type ladders, the instant invention teaches a ladder which, when in use, provides a relatively rigid structure, while still permitting the ladder to be folded or collapsed into a small space.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary large scale perspective view of a ladder according to an embodiment of the instant invention:
FIG. 2 is a perspecitve view of a modification of a partially open ladder of FIG. 1, showing the top step of the ladder mounted on the inside of a storage container;
FIG. 3 is a perspective view similar to FIG. 2 in the fully open position;
FIG. 4 is a perspective view similar to FIG. 2 showing a modification that includes a stacking rod;
FIG. 5 is an enlarged fragmentary view, partially in section of the modification of FIG. 4, of the upper end of the stacking rod secured in place with a quick disconnect retaining ring; and
FIG. 6 is an enlarged fragmentary side elevational view of a modified embodiment that includes an adjustment linkage for the window rods.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In carrying the invention into effect in the embodiment which have been selected for illustration in the accompanying drawings and for description in this specification, and referring now particularly to FIG. 1, a plurality of steps 11 are supported, one below the other to form a ladder, by a plurality of rigid links 12. The links 12 are pivotally secured together and to the steps 11 by pivot pins 13.
The pivot pins 13 are supported, in the links 12, by pivot pin bearing means such as bearings 14, 16 and 17, respectively. These bearing means 14, 16, are so formed and disposed as to permit pivotal securing together of adjacent links 12 using a single pivot pin 13. Thus, in the preferred embodiment shown in FIG. 1, the bearing 16 comprises a single arm 18 with a bore 19 therethrough. The bearing 14 comprises two arms 21, 22 spaced apart for a distance to permit the arm 18 of the bearing 16 to fit therebetween. Each arm 21, 22 of the bearing 14 has a bore 23' therethrough wherein a pivot pin 13 can be inserted through the bore 19 of the arm 18 to journal the arms 18 and 21, 22 pivotably together.
The desired direction of fold of adjoining links 12 is shown in FIG. 1 by arrows A and B. To help restrain folding in an undesirable outward direction, stop means may be provided such as a projection 15 that is formed on the bearing 16, as shown in FIG. 1.
To provide for the pivotal securing of a step 11 to the links 12, in the preferred embodiment shown in FIG. 1, the bearings 17 are provided in the step 11. As shown, these may take the form of arms 23, 24 that extend on opposite sides of the step 11, and are spaced apart for a distance sufficient to permit the arms 18, 21, 22 of the links 12 to fit therebetween. By providing bores 26 in these arms, which bores line up with the bores 19 and 23' in the arms 18, 21, 22 provided in the links 12, a single pivot pin 13 can be received by the bearings 14, 16 and 17 simultaneously. For reasons of safety, the pivot pins 13 can be trimmed to a length that will not protrude beyond the outermost arms.
In order to secure the ladder to a window, hand rails or window rods 27 may be provided. As shown in FIG. 1, the hand rails 27 also form the top pivot pin and are therefore pivotally secured to the ladder.
The ladder may also be provided with apertures such as hand holds 28 in the steps 11, and with hand holds 29 in the links 12, for the convenience of a person using the ladder. The hand holds may, of course, take other forms, for example the links 12 can be made in the form of an "I" wherein one can easily grab the narrow center or web portion of the "I" shape linkage (this embodiment is not shown). The steps 11 may also be formed with ridges 30, molded or otherwise formed therein. These ridges 30 act to provide a relatively non-slip surface on the steps 11. Other non-slip surfaces may be provided instead, as would be evident to a person skilled in the art.
When the ladder is intended for use as a fire escape means, the ladder may be too long to fold conveniently without additional aid. Therefore, apertures 20 may be formed in the steps 11, essentially aligned with each other and a rope or similar means (not shown) can be passed through these apertures 20 and be attached to the bottom step. One need only pull up on the rope, by hand or with a simple winch device (not shown), to fold the ladder for storage.
Other uses for a foldable ladder as herein described, would be obvious to persons using foldable ladders. An example of such a use would be in marine applications wherein a ladder is often used to board a boat from the water.
The material from which the ladder should be manufactured will depend on its final use. Thus, for fire escape purposes, a flame-retarding polymer or similar material (Lexan - S.E., A.B.S., glass-filled material, fiber-filled material) may be used. These materials for the most part, may be conveniently molded into appropriate parts for both the steps and the linkages. The pivot pins may also be of a synthetic polymer or of a metal such as steel.
If used for marine purposes, the possibility of corrosion or other deterioration associated with such applications, must be taken into account when deciding the material to be used.
The ladder may also be provided with a plurality of stand-offs 25 extending from the ladder. These act to keep the ladder apart from a wall or side of a boat or other downwardly extending part of the structure to which the ladder is secured.
In the embodiment shown in FIG. 2, the ladder is shown secured to a storage container such as a box 31, mounted outside of a window. The ladder is pivotally secured to the inside of the box 31. A hand rail or window rod 32 (similar to the hand rail 27 of FIG. 1) is shown secured to the box 31. Although much of the detail of the ladder has been omitted from FIG. 2, for the sake of clarity, the manner of folding the ladder can be seen and is similar to that of FIG. 1. FIG. 2 shows the ladder in a partially folded position.
Adjacent links 12, pivot or fold towards each other on each side of the ladder. This results in the steps 11 moving towards each other to form a small, folded, structure. For the embodiments shown in FIG. 2, the ladder is pulled up into the box 31 and a cover (not shown) is placed over the box 31 to protect and hold the ladder.
When the ladder is to be used, its links will be extended to unfold the ladder, and the window rod 32 will engage the window sill, all as shown in FIG. 3.
Referring to FIGS. 4 and 5, the ladder may also be provided with a stacking rod 33 which simultaneously passes through apertures 20 to aid in maintaining the steps 11 in an aligned relation to each other when the ladder is folded. The stacking rod 33 has an enlarged portion 34 at one end to prevent that end from passing through apertures 20. The other end of the rod 33 is provided with a releasable enlarged portion such as a quick disconnect retaining ring 36, shown in detail in FIG. 5. A reinforcing collar 37, shown in FIG. 5, may be molded into the steps 11 to provide reinforcement around the apertures 20.
A further modification, which aids in providing a more rigid feeling ladder for the person using it, provides for a length adjustment means such as adjustment linkage 35, for the hand rail 27a, as shown in FIG. 6. The hand rail 27a of FIG. 6 is similar to hand rail 27 of FIG. 1 except that it has an adjustment means such as adjustment link 35 for securing it to the link 12. The end of the hand rail 27a is provided with a threaded rod 38 and means for adjusting the position of the link 12 with respect to the threaded rod 38, for example adjustment nuts 39. By turning the nuts 39 on the threaded bar 38, the effective length of hand rail 27a can be adjusted to the width of the window sill or other structure to which the the ladder is to be secured.
In a preferred embodiment means for shielding the threaded bar 38, such as guard 41, and for preventing accidental removal of the threaded bar 38, such as stop 42, are also provided on the ladder.
Operation
The operation of the above described embodiments of the invention is as follows:
When used as an emergency escape means, the ladder may be removed from storage and secured to a window or other convenient escape path, and permitted to unfold. The embodiment of FIG. 2 shows a ladder already secured outside of a window, and one need only release the cover of the box 31 to drop the ladder. Once the ladder is secured, for example to the window sill, as shown in FIG. 3, one need only step onto the ladder gripping the hand rail 32, and climb down. The weight of the person will act to hold the ladder relatively rigid and the stop means 15, when provided on the ladder, acts to aid in maintaining the ladder extended. Hand holds 28 and 29 may be provided for easy grasping by hand.
The ladder is folded simply by moving the steps 11 together with the links 12 folding towards each other in the direction A, B, respectively, as shown in FIG. 1. A stacking rod 33 may be inserted through apertures 20, and a quick disconnect retaining ring 36 inserted on the end passing through the apertures 20. This will aid in handling the ladder in its folded condition. If the retaining ring 36 is inserted over the end of the rod 33 protruding from the top step 11, it can be easily slipped off and the rod 33 allowed to fall out, thus releasing the ladder, as shown in FIG. 4.
The adjustment linkage 35 permits adjusting the position of the hand rail 27a relative to the ladder, whereby a firmer grip on the window sill or other wall support can be attained. This linkage 35 permits adjustment to various widths of window sills or other supports, for example the gunwalls of a boat when the ladder is used for marine purposes.
I wish it to be understood that I do not desire to be limited to the exact details of construction shown and described, for obvious modifications will occur to a person skilled in the art.
|
A foldable ladder having a plurality of rigid steps and of rigid links which steps and links are pivotally secured together with pivot pins to result in a rigid ladder in use, but capable of being folded for storage.
| 4
|
CROSS REFERENCE TO RELATED APPLICATION(S)
The present application is a continuation application of U.S. Ser. No. 11/215,778, filed on Aug. 30, 2005, now issued as U.S. Pat. No. 7,768,049, which is a divisional of U.S. Ser. No. 10/421,157, filed on Apr. 23, 2003, now issued as U.S. Pat. No. 7,049,153, which applications are herein incorporated by reference in their entirety.
BACKGROUND
Integrated memory circuits serve as data-storage components in thousands of products, from televisions, to automobiles, to computers. Often, these memory circuits are implemented as arrays of memory cells, with each memory cell storing an electrical charge representative of a one or a zero.
In recent years, these memory cells have been modified to include a layer of ceramic-based ferroelectric material that exhibits electric polarizations, analogous to north-south magnetic polarizations, in response to appropriate electrical signals. One electrical signal polarizes the material to represent a zero, and another signal oppositely polarizes the material to represent a one. The polarizations can be detected with special circuitry that allows recovery of stored data. Memory circuits using these ferroelectric memory transistors generally enjoy advantages, such as faster write cycles and lower power requirements, over conventional charge-storage memories.
More recently, polymer-based ferroelectrics have emerged as a potential substitute for ceramic-based ferroelectrics because they generally overcome or ameliorate problems, such as fatigue and imprint, that ceramic-based ferroelectrics may suffer. Moreover, polymer-based ferroelectrics are generally more amenable to use in multi-layer (stacked) memory circuits, which provide increased storage capacity. However, polymer-based ferroelectrics are not without their own problems.
For example, conventional fabrication methods that deposit the ferroelectric polymer over metal structures separated by empty gaps may create hills and valleys in the deposited ferroelectric material. The changing thickness of the ferroelectric material is undesirable, because it not only causes cell-to-cell performance variations, but also produces too many defective cells and thus reduces manufacturing yield. Poor yield ultimately raises the cost of manufacturing these type memories. Moreover, as the number of layers in a multi-layer memory increases, the hills and valleys tend to become higher and deeper, exaggerating the thickness variations in the deposited ferroelectric material and further detracting from desired performance and yield.
Accordingly, the present inventors have recognized a need for developing other methods of making polymer-based ferroelectric memories.
SUMMARY
To address these and other needs, unique methods, structures, circuits, and systems for polymer-based ferroelectric memories have been devised. One method entails forming an insulative layer on a substrate, forming two or more first conductive structures, with at least two of the first conductive structures separated by a gap, forming a gap-filling structure within the gap, and forming a polymer-based ferroelectric layer over the gap-filling structure and the first conductive structures.
In some embodiments, forming the gap-filling structure entails depositing a spin-on-glass material within the gap between the two first conductors and/or depositing a polymer-based material. For example, one embodiment deposits a polymer-based materials having a different solvent concentration than that used for the polymer-based ferroelectric. Still other methods extend the use of gap-filling structures to subsequent layers in a multi-layer memory circuit.
Other aspects of various embodiments include arrays of memory cells and memory circuits.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of an integrated-circuit assembly including a substrate 12 , lower electrode structures 14 , 16 , and 18 , and gaps 15 and 17 .
FIG. 2 is a cross-sectional view of the FIG. 1 assembly after forming gap-filling layer 20 , which includes gap-filling structures 22 and 24 .
FIG. 3 is a cross-sectional view of the FIG. 2 assembly after forming polymer-based ferroelectric layer 30 .
FIG. 4 is a cross-sectional view of the FIG. 3 assembly after forming conductive layers 32 A, 32 B, and 32 C atop polymer-based ferroelectric layer 30 .
FIG. 5 is a cross-sectional view of the FIG. 4 assembly, taken along line 5 - 5 , after forming upper electrode structures 34 , 36 , and 38 .
FIG. 6 is a cross-sectional view of the FIG. 5 assembly after forming gap-filling layer 40 , to complete a first cross-point polymer-based memory array 60 .
FIG. 7 is a cross-sectional view of the FIG. 6 assembly after forming a second cross-point polymer-based memory array structure 60 ′ atop memory array 60 .
FIG. 8 is a cross-sectional view of a cross-point polymer-based memory array structure, which is similar to array 60 in FIG. 6 , but includes floating gate polymer-based memory transistors, such as transistor 80 .
FIG. 9 is a cross-sectional view of an integrated-circuit assembly including a substrate 12 which has a number of trenches, such as trenches 92 , 94 , and 96 .
FIG. 10 is a cross-sectional view of the FIG. 9 assembly after formation of lower electrode structures 102 , 104 , and 106 in the trenches.
FIG. 11 is a cross-sectional view of the FIG. 10 assembly after formation of a polymer-based ferroelectric layer 110 over lower electrode structures 102 , 104 , 106 .
FIG. 12 is a cross-sectional view of the FIG. 11 assembly taken along line 12 - 12 of FIG. 11 , after formation of upper electrode structures 122 , 124 , and 126 on polymer-based ferroelectric layer 110 .
FIG. 13 is a block diagram of a system including a polymer-based ferroelectric-memory circuit that incorporates ferroelectric memory arrays and/or other structures according to the present invention.
DETAILED DESCRIPTION
The following detailed description, which references and incorporates FIGS. 1-13 , describes and illustrates specific embodiments of the invention. These embodiments, offered as examples, are shown and described in sufficient detail to enable those skilled in the art to implement or practice the invention. Thus, where appropriate to avoid obscuring the invention, the description may omit certain information known to those of ordinary skill in the art.
FIGS. 1-7 show a number of integrated-circuit assemblies, which collectively illustrate at least one method of fabricating polymer-based ferroelectric memory arrays according to the present invention. (Other embodiments may be formed by changing the order of formation or by combining or eliminating formation or processing of certain features.) FIG. 8 shows alternative polymer-based memory array using floating-gate transistors. FIGS. 9-12 collectively illustrate another method of fabricating polymer-based ferroelectric memory arrays according to the present invention. FIG. 13 shows a random-access-memory circuit incorporating ferroelectric memory transistors or memory cells of the present invention.
Fabrication Methods and Structures for Ferroelectric Memories
The first method, as shown in FIG. 1 , begins with formation of a number of lower electrode structures, such as electrode structures 14 , 16 , and 18 , on a surface of a substrate 12 . The term “substrate,” as used herein, encompasses a semiconductor wafer as well as structures having one or more insulative, semi-insulative, conductive, or semiconductive layers and materials. Thus, for example, the term embraces silicon-on-insulator, silicon-on-sapphire, and other advanced structures.
In this embodiment, substrate 12 comprises an insulative layer, which itself lies on a layer of semiconductive material (not shown). Useful insulative materials include silicon dioxide, silicon nitrides, silicon oxynitrides, or carbides. Useful semiconductive materials include silicon, silicon carbide, and silicon germanium. However, other embodiments may use different materials. This method forms the insulative layer through oxidation of the semiconductive surface. Other embodiments, however, may grow or deposit another insulative material. In some embodiments, substrate 12 comprises a layer of polymer, for example, a ferroelectric polymer, which is processed as a continuous roll.
More specifically, lower electrode structures 14 , 16 , and 18 include respective 5-100-nanometer-thick titanium layers 14 A, 16 A, and 18 A; respective 20-1000-nanometer-thick aluminum layers 14 B, 16 B, and 18 B; and respective 5-100-nanometer-thick titanium-nitride layers 14 C, 16 C, and 18 C. (Other embodiments form layers 14 C, 16 C, and 18 C using tantalum nitride, tungsten, and tungsten nitride.) Lower electrode structures 14 and 16 are separated by a gap 15 , and lower electrode structures 16 and 18 are separated by a gap 17 .
In this embodiment, forming the lower electrode structures entails sequential deposition of titanium, aluminum, and titanium nitride to form respective titanium, aluminum, and titanium-nitride layers. The titanium layer is then masked to define parallel conductive traces (which appear as islands in this cross-sectional view) and all three layers are etched down to (or into) substrate 12 .
Some embodiments form the conductive layers of the electrode structures from different materials. For example, some embodiments replace the titanium-nitride layer with a platinum-based layer or a tantalum-nitride layer. And, some embodiments replace the aluminum layer with a copper-, sliver-, or gold-based metallic layer. Some embodiments may use non-metal conductive materials. Note that some embodiments form an adhesion layer on the substrate as preparation for the titanium or other metal.
FIG. 2 shows that after forming the lower electrode structures 14 , 16 , and 18 , the method forms a gap-filling layer 20 , which substantially fills gaps 15 and 17 (in FIG. 1 ) with respective gap-filling structures 22 and 24 . In some embodiments, gap-filling layer 20 , which has a thickness that is 20-200 nanometers or 10-100 percent thicker than the height of the lower electrode structures, comprises an insulative material, such as a spin-on-glass material, a Flow-Fill™ oxide, a high-density-plasma (HDP) oxide, or an insulative polymer. (Flow-fill may be a trademark of Electrotech Limited of Bristol, United Kingdom. For further information regarding a flow-fill technique, see, for example, U.S. Pat. No. 6,372,669, which is assigned to the assignee of the embodiments described in this document, and incorporated herein by reference in its entirety.) In some other embodiments, gap-filling layer has thickness which makes it substantially flush with the lower electrode structures. After deposition of the gap-filling layer, one or more portions of the layer overlying the lower electrode structures are removed using a wet or dry etch or a chemical-mechanical planarization technique.
In some embodiments that use an insulative polymer filler, the polymer includes a polymer-based ferroelectric material. (As used herein, the term “ferroelectric,” indicates that a subject material, material composition, or material structure, exhibits a detectable spontaneous electrical polarization in response to appropriate electrical stimulus. Thus, the term without other express contextual modification or qualification generally encompasses elemental ferroelectric materials as well as combination and composite ferroelectric materials.) Useful ferroelectric polymers include polyvinylidene fluoride (PVDF), trifluoroethylene, (TrFe), and co-polymers of PVDF and TrFe. Useful co-polymers include the PVDF and TrFe in concentrations ranging from 10-90 percent. However, other embodiments may use other concentrations.
Some embodiments optimize the spin-characteristics of the ferroelectric polymer by controlling solvent concentrations. Useful solvent concentrations range between 20-80 percent. Such optimization can be achieved by changing the molecular weight distribution, copolymer composition, and/or polymer thickness.
FIG. 3 shows that after forming gap-filling structures 22 and 24 , the method entails formation of a polymer-based ferroelectric layer 30 . More specifically, this polymer-based ferroelectric layer is formed to a thickness of 10-1000 nanometers. In this embodiment, polymer-based ferroelectric layer 30 has different characteristics than the gap-filling layer, more precisely polymer-based gap-filling structures 22 and 24 . Specifically, unlike the polymer-based gap-filling structures 22 and 24 , which is optimized for spin casting, polymer-based ferroelectric layer 30 is optimized for other properties, such as its ferroelectricity.
Notably, polymer-based ferroelectric layer 30 contacts only the gap-filling material ( 20 , 22 , 24 ) and the uppermost layers of lower electrode structures 14 , 16 , and 18 . In some conventional polymer-based memory structures, the lower electrode structures are formed by lining a trench or other opening in an insulative surface with a diffusion barrier metal and then filling the lined trench with a second metal. In these conventional cases (which also lack the gap-filling layer and associated gap-filling structures), the polymer-based ferroelectric material therefore contacts both the trench-lining metal and the fill metal. This dual-metal interface is undesirable because it produces fringing fields.
FIG. 4 shows that the next step in the method entails sequentially forming conductive layers 32 A, 32 B, and 32 C atop polymer-based ferroelectric layer 30 . These conductive layers generally correspond in dimension and composition to those of lower electrode structures 14 , 16 , and 18 . More specifically, conductive layer 32 A is 5-100-nanometer-thick titanium layers 14 A; conductive layer 32 B is a 20-1000-nanometer-thick aluminum layer; and conductive layer 32 C is a 5-100-nanometer-thick titanium-nitride layer. However, some embodiments use other materials and dimensions, as described for the lower electrode structures.
FIG. 5 , a cross-sectional view taken along line 5 - 5 of FIG. 4 , shows that after forming conductive layers 32 A, 32 B, and 32 C, the method forms these layers into upper electrode structures 34 , 36 , and 38 . Formed orthogonal to the lower electrode structures 14 , 16 , and 18 , and separated by gaps 35 and 37 , upper electrode structures 34 , 36 , and 38 include respective 5-100-nanometer-thick titanium layers 34 A, 36 A, and 38 A; respective 20-1000-nanometer-thick aluminum layers 34 B, 36 B, and 38 B; and respective 5-100-nanometer-thick titanium-nitride layers 34 C, 36 C, and 38 C. Notably, the thicknesses of the respective portions 30 A, 30 B, and 30 C of polymer-based ferroelectric layer 30 separating each upper electrode structure from its counterpart lower electrode structure are substantially equal, even at the edges of the substrate.
In this embodiment, forming the upper electrode structures entails masking titanium-nitride layer 34 to define bars and etching it and layers 36 and 38 down into polymer-based ferroelectric layer 30 . The depth of the etch, for example 2-30 percent of the layer thickness, is generally sufficient to ensure separation of the upper electrode structures.
FIG. 6 shows that the method next forms a gap-filling layer 40 , which substantially fills gaps 35 and 37 (in FIG. 4 ) with gap-filling structures 42 and 44 , and thus completes a first polymer-based memory array 60 . In this embodiment, gap-filling layer 40 , which has a thickness at least as great as the height of the upper electrode structures plus the depth of the etch into ferroelectric layer 30 , comprises an insulative material, such as a spin-on-glass material, an HDP oxide, an insulative polymer, or a polymer-based ferroelectric material, as in the formation of gap-filling layer 20 . (Using a polymer-based ferroelectric material to fill the gaps may ameliorate fringe-field issues.) Forming the layer to this height entails spin casting the material and then planarizing using chemical-mechanical planarization for example, to expose upper electrode structures 34 , 36 , and 38 . Some embodiments may expose the upper electrode structures using a dry or wet etch.
FIG. 7 shows that the next step in the method may entail building at least one additional polymer-based memory array 60 ′ atop memory array 60 to realize a multilevel memory array 70 . The fabrication of memory array 60 ′ may follow the same procedure used for memory array 60 . However, other embodiments may make material and/or dimensional changes, or use entirely different methods and materials to realize other memory arrays, analogous or non-analogous to array 60 . Although not shown, other embodiments continue by forming support circuitry and associated interconnections to realize a complete memory circuit.
FIG. 8 shows an alternative version of the integrated-circuit assembly in FIG. 3 . The alternative version includes a semiconductive substrate 12 and a number of polymer-based ferroelectric floating gate transistors, of which transistor 80 is representative.
Transistor 80 includes self-aligned source/drain regions 82 and 84 , a semiconductive channel region 83 , and a gate insulator 86 . Source and drain regions 82 and 84 , formed using a conventional ion-implantation and diffusion techniques, define the length of channel region 83 . Although this embodiment shows simple drain and source profiles, any desirable profile, for example, a lightly doped drain (LDD) profile, an abrupt junction or a “fully overlapped, lightly doped drain” (FOLD) profile, may be used. (Some profiles entail formation of insulative sidewall spacers on the lower electrode structure, before executing the ion-implantation procedure that forms the drain and source regions.) Gate insulator 86 , which consists of a silicon oxide or other suitable dielectric material, lies between channel region 83 and lower electrode structure 14 . Drain and source contacts (not shown) are formed and interconnected as desired to complete an integrated memory circuit
In operation, the polarization state of a portion of the polymer-based ferroelectric in memory arrays described herein can be controlled by applying appropriate voltages to the electrode structures and/or to the gate, source and drains. Conventional circuitry and related techniques can also be used for sensing the polarization state of each memory cell in the arrays.
FIGS. 9-12 show another series of integrated-circuit assemblies which sequentially and collectively illustrate another method of making a polymer-based ferroelectric memory array. (Other embodiments may be formed by changing the order of formation or by combining or eliminating formation or processing of certain features.) This method, as shown in FIG. 9 , begins with forming in substrate 12 a number of trenches, such as trenches 92 , 94 , and 96 . The trenches may be formed using any available technique appropriate for the composition of substrate 12 . For example, if substrate 12 is an insulative material, such as silicon dioxide, one may form the trenches using conventional photolithographic techniques.
Next, FIG. 10 shows that this method forms lower electrode structures 102 , 104 , and 106 in the trenches. More specifically, this entails blanket depositing a conductive material, such as aluminum or titanium, over the trenches and surrounding substrate regions, with the layer having a thickness greater than the depth of the trenches. After the blanket deposition, the method removes conductive material outside the trenches using a planarization process, such as chemical-mechanical planarization. In this embodiment, planarization removes substantially all conductive material outside the trenches and leaves the conductive material within the trenches substantially flush with the top surface of the substrate, ultimately defining the lower electrode structures. Some other embodiments may form the lower electrode structures as multilayer structures, analogous to previously described lower electrode structures 14 , 16 , and 18 .
FIG. 11 shows the results of forming a polymer-based ferroelectric layer 110 over lower electrode structures 102 , 104 , 106 . It is expected that the aluminum or titanium composition of the lower electrode will provide sufficient adhesion and diffusion-barrier properties to interface effectively with the polymer-based ferroelectric layer. Notably, this form of material interface, like the previous embodiment, avoids undesirable fringing fields that result from multiple metallic layers contacting the polymer-based ferroelectric layer.
FIG. 12 , a cross-sectional view taken along line 12 - 12 of FIG. 11 , shows that the method may next faun upper electrode structures 122 , 124 , and 126 on polymer-based ferroelectric layer 110 . These upper electrodes generally correspond in dimension and composition to those of lower electrode structures 102 , 104 , and 106 .
More precisely, this embodiment forms the upper electrodes by forming trenches in polymer-based ferroelectric layer 110 that are transverse or orthogonal to the lower electrodes, blanket depositing aluminum or titanium over the trenches and surrounding regions, and then removing substantially all the metal outside the trenches using a planarization process, such as chemical-mechanical planarization. The planarization ultimately forms upper electrode structures that are substantially flush with a top surface of the polymer-based ferroelectric layer, thus completing a polymer-based memory array 130 . Some other embodiments may form the upper electrode structures as multilayer structures, analogous to previously described structures 34 , 36 , and 38 .
Further processing can be used to define one or more additional polymer-based memory arrays atop memory array 130 to produce a multi-level memory analogous to multilevel memory array 70 in FIG. 7 . Additionally, further processing may also define a number of polymer-based ferroelectric floating gate transistors.
Systems and Circuits
FIG. 13 shows a computer system 1300 including a memory circuit 1310 , a processing unit 1320 , input-output devices 1330 , data-storage 1340 , and a bus 1350 . Memory circuit 1310 , which operates according to well-known and understood principles and is coupled to one or more other components of the system via bus 1350 , includes one or more memory arrays 1312 , a row address decoder 1314 , a column address decoder 1316 , a level address decoder 1318 , and sense circuitry 1319 .
In this embodiment, memory arrays 1312 incorporate one or more of the memory arrays or intermediate integrated-circuit assemblies based on teachings of the present invention. Also, in this embodiment, memory arrays, the address decoders, and the sense circuitry exist in a single integrated circuit. However, in other embodiments, one or more may exist on separate integrated circuits.
Processing unit 1320 , input-output devices 1330 , and data-storage devices 1340 are intercoupled conventionally via bus 1350 . Processing unit 1320 includes one or more processors or virtual processors. Input-output devices 1330 includes one or more keyboards, pointing devices, monitors, etc. And data-storage devices 1340 include one or more optical, electronic, or magnetic storage devices.
CONCLUSION
In furtherance of the art, the inventors have presented unique methods and structures for polymer-based ferroelectric memories. One method entails forming two or more first conductive structures on a substrate, with at least two of the first electrode structures separated by a gap, forming a gap-filling structure within the gap, and forming a polymer-based ferroelectric layer over the gap-filling structure and the first electrode structures. Two or more second electrode structures are then formed over the polymer-based ferroelectric layer, orthogonal to the first electrode structures. Notably, the gap-filling structures may facilitate formation of a substantially planar and uniformly thick polymer-based ferroelectric layer, thereby promoting memory performance and yield.
The embodiments described above are intended only to illustrate and teach one or more ways of practicing or implementing the present invention, not to restrict its breadth or scope. The actual scope of the invention, which embraces all ways of practicing or implementing the invention, is defined only by the following claims and their equivalents.
|
Apparatus and systems may comprise electrode structures that include two or more dissimilar and abutting metal layers on a surface, some of the electrode structures separated by a gap; and a polymer-based ferroelectric layer overlying and directly abutting some of the electrode structures. Methods may comprise actions to form and operate the apparatus and systems. Additional apparatus, systems, and methods are disclosed.
| 7
|
This application is a divisional of application Ser. No. 09/987,673, now U.S. Pat. No. 6,932,869 B2, filed Nov. 15, 2001, and issued on Aug. 23, 2005. the entire disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to the field of optical fibers, in particular the present invention is directed to using ultrasound to aid in the curing of UV-curable coatings of optical fibers.
2. Discussion of Related Art
Optical fibers are very small diameter glass strands which are capable of transmitting an optical signal over great distances, at high speeds, and with relatively low signal loss as compared to standard wire or cable networks. The use of optical fibers in today's technology has developed into many widespread areas, such as: medicine, aviation, communications, etc. Because of this development, there is a growing need to produce optical fibers of better quality at faster rates and lower costs.
Many of the areas of use for optical fibers, such as communications, require the optical fibers be protected from various destructive elements, such as adverse weather, moisture, impact damage, etc. This protection for the individual fibers comes from the fiber coatings. Today, most optical fibers have two coatings, which are often referred to as the primary and secondary coatings. The primary coating is applied onto the surface of the optical fiber, with the secondary coating being applied on top of the primary coating. The main function of the primary coating is to provide a soft “cushion” for the glass fiber, protecting it from shock damage. The main purpose of the secondary coating is to provide a semi-rigid protective shell to protect both the primary coating and the glass fiber from adverse environmental elements, as well as physical damage.
One of the most common methods of making optical fibers today is by a process often referred to as the “draw” process. In this process, a large glass preform is made. The preform is the actual material that the glass fiber (optical fiber) is made from. Once the preform is made, the next step is to “draw” the preform into a glass fiber (optical fiber) with the desired diameter. One of the most common means to accomplish this is through the use of a “draw tower”. The “draw tower” is a production apparatus which has all of the major stages required to manufacture an optical fiber from a glass preform to the finished fiber. In this process the glass preform is typically suspended above the apparatus with the bottom most end of the preform entering into a furnace. The furnace uniformly melts the preform such that the preform exits the furnace as a very thin diameter optical glass fiber. The rate the preform is moved into the furnace can be regulated to allow the maintenance of a constant diameter in the optical fiber. Once the glass fiber leaves the furnace it is generally cooled.
After the glass fiber is cooled to a preset temperature then the fiber is typically coated with the primary coating. This is generally done in a coating die. The primary coating is applied in such a way as to completely cover the fiber. The primary coating is then cured or hardened. Once the primary coating has been cured or hardened, the secondary coating is then applied to completely cover the primary coating. The secondary coating is then cured so as to harden it and secure it to the primary coating. Once this process is complete then the fiber is generally considered an optical fiber, as commonly known and understood. Finally the optical fiber is wound past a capstan and onto a reel or spool.
The coatings of the optical fiber are mainly used to provide chemical, mechanical and environmental protection to the glass fiber core and cladding. To accomplish this purpose the two layers are usually made from different materials. Generally the primary coating is relatively soft (having a relatively low Modulus of Elasticity of 1–2 MPa) when compared to the secondary coating and is used as a cushion or shock protection for the glass fiber. The secondary coating is relatively hard (having a relatively high Modulus of Elasticity of 30–60 MPa) and provides a semi-rigid protective shell for the fiber and primary coating. The most common types of coatings used are ultraviolet (UV) curable coatings. These are coatings which have a photoinitiator component used in the coating composition which allow the curing of the coatings to be initiated by exposure to UV radiation.
Photoinitiators function by absorbing energy which is radiated by a UV, or sometimes a visible, light source. This energy absorption then initiates polymerization of the liquid coating placed on the fiber, and results in the hardening of the coating. The fast cure of coatings greatly reduces the production time of optical fibers, making production more profitable.
However, this method of curing optical fiber coatings is not without its problems. Among other things, the curing process can generate a large amount of heat in the coatings of the fiber. This heat generally comes from hot UV/Visible lamps by convection or by infrared irradiation accompanying the UV- or visible light of a lamp during cure, and from the exothermic polymerization (i.e. cure) itself. This heat also contributes in curing the coatings, but can cause serious problems. For instance, if the temperature of coating during cure is too high it may result in decomposition of microradicals in the coating material and result in a low degree of cure. Overall, it is generally known that excessive heat during the coating cure process is detrimental for efficient or effective cure by free radical polymerization.
As stated earlier, the primary coating should be relatively soft, to protect the glass fiber from microbending. Microbending is the formation of microscopic bends in the glass fiber, which will reduce the effectiveness of the fiber by reducing the magnitude of transmitted light power, i.e. attenuation. In the cure process the primary coating is applied and then cured, and then the secondary coating is applied and then cured. As the secondary coating is being cured, the primary coating is, and often additionally, cured up until 100% conversion of the coating monomer(s) into polymers.
Because of the problems associated with the generation of excessive heat during the cure process, many prior art methods have been developed to expedite the cure process without the generation of excessive heat. An example would be to reduce the level of UV radiation, however, with the reduction of UV radiation the line speed must be slowed to ensure that the coating receives the proper amount of UV exposure to effect a proper cure. This reduction in draw speed can severely affect the manufacturing efficiency of a fiber optic facility. It is desired to have a system of curing optical fiber coatings at as high a speed as possible.
SUMMARY OF THE INVENTION
The present invention is directed to a system and apparatus for curing optical fiber coatings at high line speeds. To accomplish this the present invention uses a combination of UV radiation and ultrasound to cure the optical fiber coatings.
In the present invention, an ultrasonic transducer is placed at a stage, along the fiber draw tower to emit ultrasound at the drawn fiber and coating to aid in the coating cure process. (It is noted, and further discussed below, that the present invention also contemplates the use of a plurality of transducers at various locations along the draw tower.) By using ultrasound to aid the coating cure process the polymerization of the coating material can be accelerated.
In the present invention, an ultrasonic transducer can be attached to many of the components in a fiber draw tower but preferably should be coupled to either the fiber coating die, which applies the coating to the drawn fiber, or to the quartz tube through which the fiber is drawn when it undergoes its UV radiation curing, or both. Further, the ultrasonic emissions by the transducers can be either done in pulses or through constant excitation depending on the manufacturing and production needs.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages, nature and various additional features of the invention will appear more fully upon consideration of the illustrative embodiment of the invention which is schematically set forth in the drawing, in which:
FIG. 1 is a diagrammatical representation of a optical fiber coating and cure apparatus according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be explained in further detail by making reference to the accompanying drawings, which do not limit the scope of the invention in any way.
Turning now to FIG. 1 , optical fiber coating and cure stages according to the present invention are shown. As shown in FIG. 1 , a fiber 10 is drawn along a draw line and passes through a coating die 12 , which deposits the coating material onto the fiber 10 . The coating die 12 can be for either the primary or secondary coating of an optical fiber, and can deposit onto the fiber 10 any coating material whose curing is benefited by the use of ultrasonic excitation. In the present invention, any commonly known or used coating material can be used. However, it is preferred that the coating be a di-functional urethane acrolate.
In an embodiment of the present invention, an ultrasonic transducer (or transducers) 11 is coupled to the coating or the coating die 12 such that the ultrasonic waves excite the liquid coating as it is being applied to the fiber 10 . This excitation aids in the polymerization of the coating on the fiber, thus aiding in the curing process. In the preferred embodiment, the ultrasonic frequency used is between −2×10 4 to 10 9 Hz, however, it is noted that the present invention is not limited to use in this range, and more particularly the optimum frequency to be used should be determined and optimized based on the coating material used. It is further noted that the ultrasound can also be applied in pulses or bursts.
The application of the ultrasound to the coating or the coating die 12 causes cavitation in the liquid coating material and in a non-completely cured coating results in the formation of additional free radicals (i.e. sonolysis), which increases the rate and efficiency of the cure. Further, it also increases the mobility and motion of oligomer ends in the coating material, thus increasing the number of polymerization additions per unit time, i.e. increasing the rate of propagation of polymerization at all stages of the cure process. It should be noted that determination of the optimal frequency should be done for each type of coating used. The proper frequency should accelerate relaxation of the formed polymeric coating to its most thermodynamically stable conformation and to increase the Modulus of the coating. However, if the ultrasound is too powerful it may damage the coating or the fiber.
After the fiber 10 passes through the coating die 12 , which may or may not have a transducer(s) 11 coupled to it (or the coating within the die), the fiber 10 passes through a UV curing stage. Common UV curing stages comprise a reflector 13 to reflect UV rays from the UV bulb 14 onto the fiber 10 . They further comprise a quartz tube 15 , through which the fiber 10 passes to protect the fiber 10 from the high velocity cooling gases used to keep the bulb 14 cool. In an alternative embodiment of the present invention, an additional transducer 11 is coupled to the quartz tube 15 in the UV curing stage. The transducer 11 should be mounted such that the center of the tube 15 vibrates with the ultrasonic frequency emitted from the transducer 11 , thus causing the fiber 10 coating to vibrate at the desired frequency (which in the preferred embodiment is in the range of 2×10 4 to 10 9 Hz). This is because the lower frequencies of ultrasound can be transmitted through the air over the short distances inside the tube 15 . The vibrational energy from the ultrasound aids the polymerization of the UV cure process and accelerates the speed at which a proper cure can occur.
Most common ultrasonic transducers comprise an ultrasonic horn. In the preferred embodiment of the present invention, the tip (or tips) of the ultrasonic horn (or horns if more than one are used) are positioned such that they make contact with the coatings. For example, a transducer 11 positioned in the coating die 12 should have its tip inserted into the coating material, or if the a transducer 11 is positioned after the coating die 12 but prior to the UV curing stage its tip should positioned such that it makes contact with the coating to be cured. In yet another alternative embodiment, a transducer 11 is used after the UV curing stage to aid in completing the cure of the coating. In this embodiment it is possible to use a lesser than normal amount of UV cure (to keep the heat generated to a minimum) while completing the cure of the coating with the application of ultrasound according to the present invention. Again, in this embodiment it is preferred that the tip of the transducer horn make contact with the coating to be cured.
In the preferred embodiment of the present invention, a plurality of transducers 11 a are placed circumferentially around the fiber 10 after the fiber coating die 12 , but prior to the fiber entering the UV cure stage 13 , 14 , 15 . In this embodiment, a plurality of transducers are placed circumferentially around the fiber 10 to effect an even peripheral cure around the fiber 10 . Although one transducer may be used, it is preferred to have at least two transducers 11 a positioned 180 degrees to each other (at opposite sides of the fiber 10 ) or have three transducers positioned 120 degrees to each other. In this embodiment, the tips of the transducers 11 a should make contact with the coating to ensure optimum cure performance. It should be noted that as an alternative to the above preferred embodiment, it is also contemplated that instead of using a combination of transducers 11 a (as described above) a single transducer 11 a can be used with an annular collar (not shown). In this embodiment, the fiber passes through an annular collar which acts as a cylindrical resonator to effect resonation in the fiber 10 coating. It is preferred that the interior surfaces of the collar be coated with a lubricant which is compatible with the coating material to ensure that the coating does not stick to the inside of the collar. An example of such a coating would be Teflon®. In this configuration, a single (or multiple) transducer 11 a is coupled to the collar, thus preventing the need for the transducer 11 a to be contacting the coating.
In yet other embodiments of the present invention, a transducer 11 can be added to a sheave at the base of the draw tower, or at any other location along the height of the draw tower. It should be noted that the present invention is not limited to any one configuration and location of the transducers 11 , and they can be located at any one, two or all of the above referenced locations in a fiber draw tower, in addition to others. Exact placement, attachment, and location of the transducers 11 should be optimized for each manufacturing facility and technique. Further, the frequencies used should also be optimized depending on the coating materials used and the frequencies needed to optimize the cure process. Although it is preferred that in a configuration where multiple transducers 11 are used the transducers emit the same frequency, it is contemplated that with certain coatings and to meet certain manufacture specifications frequencies at different transducers 11 along a draw tower may emit different frequencies to optimize the cure of the fiber coatings.
It is important to note that the above invention is not limited to the manufacture of optical fibers, but can be applied in any situation where a material is heat or thermally cured. Further, the present invention can be used during the manufacture of fiber optic ribbons or other situations where groups of components are secured to each other with a matrix material that is cured thermally, and positively reacts to ultrasonic excitation.
It is of course understood that departures can be made from the preferred embodiments of the invention by those of ordinary skill in the art without departing from the spirit and scope of the invention that is limited only by the following claims.
|
An improved method for curing coatings on optical fibers, without creating additional heat and compromising the manufacturing speed of optical fibers. The method of curing a coating on an optical fiber includes the steps of passing an optical fiber through a coating die, applying a coating to the optical fiber, curing the coating on the optical fiber and exposing the optical fiber to ultrasound to facilitate curing of the coating.
| 2
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to methods, apparatus and systems for opposing pressure-induced loads acting upon downhole equipment components. In one embodiment, for example, the invention relates to methods, apparatus and systems capable of at least partially offsetting pressure-induced forces acting upon the mandrel and resulting forces on the shear element of a downhole packer system.
[0003] 2. Description of Related Art
[0004] In the petroleum exploration and recovery industries, equipment used in subsurface wells is often subject to various pressure-induced loads. For example, “packers” are commonly employed in subsurface wells for securing the position of tubing or other equipment in the well, and for zonal isolation to allow various treatments, or operations, to be conducted. A typical packer includes, among other components, a mandrel having a conduit in fluid communication with the tubing, one or more slips that anchor the packer to the wellbore or casing, one or more elastomeric elements that seal the wellbore at the packer, and one or more shear elements to enable emergency unset of the packer, or some combination thereof. The shear element is typically located on the mandrel and engages the mandrel with other packer components.
[0005] In use, the typical packer is set at the desired location in the wellbore. A tension-set type packer, for example, is set by applying tension to the tubing on which the packer is conveyed into the wellbore. Such tension is transferred through the mandrel and shear element, such as a shear ring, to the elastomeric element(s) and slip(s), energizing the elastomeric element and forcing the slip into contact with the wellbore wall. In any case, after the packer is set, treating pressure can be applied through the tubing to the isolated wellbore below the packer. The treating pressures cause loads to be placed upon the mandrel, referred to herein as “pressure-induced forces” (F 1 ). Examples of pressure-induced forces may include tubing forces arising from pressure ballooning of the tubing and friction of fluid pumped through the tubing. The pressure-induced forces are transferred from the mandrel through the shear element to the packer's elastomeric element and slip. Under such forces, the shear element is often forced upwardly into contact with other components of the packer system, imparting shearing loads, or resisting mechanical forces, upon the shear element.
[0006] As a result of pressure-induced forces placed upon downhole equipment in the petroleum exploration and recovery industries, limitations are placed upon downhole equipment and/or operations. For example, if the pressure-induced forces upon the shear element of a packer system exceed its shear rating, the shear element may fail. Thus, while the shear element must be designed to fail, or shear, under a certain tension to allow emergency unsetting of the packer, it must also be designed to withstand certain pressure-induced forces to avoid premature or undesirable failure during operations.
[0007] Shear elements are often designed with shear ratings sufficient to prevent shearing during normal operations, or to withstand high well treating pressures, but with an emergency unset load that may be greater than the tensile rating of the tubing. Consequently, the tubing or other equipment may fail or become damaged and/or the shear element may not shear as desired to unset the packer.
[0008] Further, in some operations, a “disconnect” may be used in conjunction with one or more downhole components, such as a bottom-hole assembly, to allow emergency disconnect of the tubing therefrom. When a packer system is also employed, the disconnect load for the disconnect must be greater than the packer shear element emergency unset load and less than the tubing tensile rating. Consequently, the inclusion of a disconnect further restricts the rating of the packer shear element and, ultimately, the allowable treating pressures during operations.
[0009] Thus, there remains a need for methods, apparatus, and/or systems capable of one or more of the following: opposing forces placed upon the shear element of a downhole component; opposing pressure-induced forces placed upon the mandrel of a packer system during use; opposing or balancing mechanical loads placed upon the shear element of a tension-set packer due to pressure-induced forces placed upon the mandrel of a packer system; compensating for upwardly acting, pressure-induced, forces on the mandrel of a packer caused by tubing pressure; opposing the tubing pressure load on a mandrel to reduce the resulting mechanical load on a shear ring of a tension-set packer system; and offsetting the generally upwardly acting mechanical loads on the shear element of a packer resulting from pressure-induced forces on the mandrel of the packer during use.
BRIEF SUMMARY OF THE INVENTION
[0010] In accordance with the present invention, certain embodiments involve an apparatus for opposing pressure-induced forces acting upon the mandrel of a packer during use of the packer in a borehole. The packer is in fluid communication with the bore of a tubing. The apparatus includes a piston housing having a cavity and a piston disposed and axially movable within the cavity. The piston is associated with a piston carrier and engageable with the mandrel of the packer. At least one port is disposed in the piston carrier above the piston and capable of allowing pressure communication between the tubing bore and the cavity above the piston, whereby forces placed upon the piston thereby are transferred to the mandrel and capable of at least partially opposing pressure-induced forces acting upon the mandrel.
[0011] Forces placed upon the piston and transferred to the mandrel may offset pressure-induced forces acting upon the mandrel. The piston, the piston carrier, and the cavity may be sized to offset the pressure-induced forces acting on the mandrel. Such forces acting on the mandrel are the result of fluid pressure acting on the mandrel cross-section, pressure ballooning or contraction of the tubing, and fluid friction acting on the tubing.
[0012] The piston may be located above the packer. At least one hole may be included in the piston housing and extend between the cavity below the piston and the borehole, the hole(s) allowing pressure communication between the borehole and the cavity below the piston.
[0013] The packer may be a tension-set packer, which may be deployed on coiled tubing. The packer may be capable of multi-set operation. The packer may include at least one shear element engaged with the mandrel, whereby forces transferred to the mandrel from the piston are applied to the shear element. The shear element(s) may be a shear ring.
[0014] In various embodiments, the present invention involves a pressure-compensating apparatus for opposing pressure-induced forces acting generally upwardly upon the mandrel of a tension-set packer during use of the tension-set packer within a borehole. The mandrel is associated with and axially movable relative to a packer housing. The tension-set packer is in fluid communication with the bore of a tubing. A piston is engageable with the mandrel, the piston being driven by pressure communicated from the tubing bore, whereby generally downwardly acting axial forces placed upon the piston from pressure communicated from the tubing bore may be transferred to the mandrel to at least partially oppose pressure-induced forces acting generally upwardly upon the mandrel.
[0015] The piston may be disposed and axially movable within a cavity, in which case the mandrel is axially movable relative to the packer housing coincident with the axial movement of the piston within the cavity. The piston may be carried by a piston carrier and at least one port may be disposed in the piston carrier and capable of allowing pressure communication between the tubing bore and the cavity above the piston. The piston and cavity may be disposed in a piston housing and at least one hole may be disposed in the piston housing to extend between the cavity and the borehole, the hole(s) allowing pressure communication between the borehole and the cavity below the piston.
[0016] The tension-set packer may be deployed on coiled tubing, and may be capable of multi-set operation. Forces placed upon the piston and transferred to the mandrel may be capable of balancing pressure-induced forces acting upon the mandrel. The piston may be located up-hole of the tension-set packer.
[0017] There are yet some embodiments of the invention that involve an apparatus for at least partially reducing mechanical forces acting upon at least one shear ring of a packer system during use of the packer system in a borehole. The shear ring is carried by a mandrel and the mechanical forces acting on the shear ring are caused by pressure-induced forces acting on the mandrel. The packer system is in fluid communication with the bore of a tubing. The apparatus includes a housing having a cavity, and a piston disposed and axially movable within the cavity. The piston is associated with a piston carrier and engageable with the mandrel of the packer system. At least one port is formed in the piston carrier above the piston, the at least one port capable of allowing fluid pressure communication between the tubing bore and the cavity above the piston. Generally downwardly acting forces placed upon the piston by pressure in the cavity are transferred to the mandrel and the at least one shear ring.
[0018] The packer system may include a tension-set packer deployed on coiled tubing, and the tension-set packer may be capable of multi-set operation. Generally downwardly acting forces placed upon the piston and transferred to the mandrel may be capable of equalizing pressure-induced forces acting upon the mandrel.
[0019] Various embodiments of the invention involve a pressure-balanced, tension-set packer system in fluid communication with the bore of a tubing. The system includes a packer housing, a mandrel associated with and axially movable relative to the packer housing and a piston engageable with the mandrel and carried by a piston carrier. The piston is disposed and axially movable within a cavity. At least one port formed in the piston carrier is capable of allowing pressure communication between the tubing bore and the cavity above the piston, whereby forces placed upon the piston may be transferred to the mandrel, at least partially opposing pressure-induced forces acting upon the mandrel. Forces placed upon the piston and transferred to the mandrel may be capable of balancing pressure-induced forces acting upon the mandrel. The tension-set packer may be capable of multi-set operations and deployed on coiled tubing.
[0020] There are yet many embodiments of the invention that involve a method for opposing generally upwardly acting, pressure-induced forces upon the mandrel of a tension-set packer during use of the packer in a borehole. The tension-set packer is in fluid communication with the bore of a tubing. This method includes connecting a piston with the mandrel, deploying the tension-set packer into the borehole, and setting the tension-set packer in the borehole. Generally upwardly acting, pressure-induced forces are allowed to act upon the mandrel, and pressure from the tubing bore is ported to the up-hole side of the piston. Generally downwardly acting forces applied to the piston are transferred to the mandrel, thereby opposing generally upwardly acting, pressure-induced forces upon the mandrel.
[0021] Such method may further include disposing the piston within a cavity, associating the piston with a piston carrier and forming a port in the piston carrier to allow the communication of pressure to the cavity above the piston from the tubing bore. If desired, the method may include designing the piston, piston carrier, and cavity so that forces transmitted to the mandrel from the piston will offset generally upwardly acting, pressure-induced forces upon the mandrel. The method may include enabling multi-set operations of the tension-set packer. If desired, the method may be conducted in a non-vertically oriented borehole.
[0022] Accordingly, the present invention includes features and advantages that are believed to enable it to advance the technology associated with compensating for pressure-induced forces on downhole equipment. Characteristics and advantages of the present invention described above, as well as additional features and benefits, will be readily apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments and referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] For a detailed description of preferred embodiments of the invention, reference will now be made to the accompanying drawings wherein:
[0024] [0024]FIG. 1 is a generally schematic view of a packer system in a neutral, unset position in a borehole, the packer system shown associated with an embodiment of a pressure compensating apparatus in accordance with the invention;
[0025] [0025]FIG. 2 is a partial cross-sectional view of an embodiment of a pressure compensating apparatus in accordance with the present invention shown used with a packer system in a set position in a borehole;
[0026] [0026]FIG. 3 is a generally schematic view of the pressure compensating apparatus and packer system of FIG. 2 with the packer in its set position; and
[0027] [0027]FIG. 4 is a generally schematic view of the pressure compensating apparatus and packer system of FIG. 3, the packer system shown in an emergency release position with the shear element sheared.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Presently preferred embodiments of the invention are shown in the above-identified figures and described in detail below. It should be understood that the appended drawings and description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. In showing and describing the preferred embodiments, like or identical reference numerals are used to identify common or similar elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.
[0029] As used herein and throughout the various portions of this patent, the terms “invention”, “present invention”, and variations thereof are not intended to mean the claimed invention of any particular of the appended claim or claims, or all of the appended claims. These terms are used to merely provide a reference point for subject matter discussed in this specification. The subject or topic of each such reference is thus not necessarily part of, or required by, any particular claim(s) merely because of such reference. Accordingly, the use herein of the terms “invention”, “present invention”, and variations thereof is not intended and should not be used to limit the construction or scope of the appended claims.
[0030] Referring initially to FIG. 1, a packer system 10 is shown associated with a pressure compensating apparatus 50 of the present invention. The illustrated packer system 10 is a multi-set, tension-set packer 12 , but can be any other type of packer system, such as a pressure-set packer system. The present invention is thus not limited to use with multi-set, tension-set type packers, and the form or operation of the packer system is not limiting upon the present invention.
[0031] The exemplary packer system 10 is shown disposed within a borehole 46 in the earth 47 in a neutral or unset position. As used herein and throughout the various parts of this patent, the terms “borehole”, “wellbore”, “well” and variations thereof means any hole, passageway or area suitable for use with the present invention. While the borehole 46 of FIG. 1 appears vertically-oriented, the present invention is not limited to any particular orientation of the borehole 46 . For example, the packer system 10 may be used in a borehole 46 that is non-vertical, such as a “horizontal” or “deviated” well. The present invention is thus not limited in any way by the type or orientation of borehole within which it is, or may be, used.
[0032] Still referring to FIG. 1, the packer 12 is shown including a mandrel 14 , packer housing 20 , one or more slips 26 , an elastomeric element 30 , and a shear element 34 , as are or become known. The shear element 34 is shown as a shear ring 36 , but can take any suitable form as is or becomes known. The illustrated mandrel 14 includes a conduit 16 in fluid communication with the axial bore 42 of a tubing 40 used to convey the packer system 10 into the borehole 46 . These components of the packer 12 , if included, may take any suitable form, and the packer 12 may include other or different elements. The tubing 40 may be any suitable tubing or other components. Thus, as used herein and throughout the various portions of this patent, the term “tubing” and variations thereof means coiled tubing, jointed drill-string elements, tubing connectors or any other suitable component(s). The present invention is thus not limited in any way by the type, configuration and form of items with which the packer system 10 is, or may be, connected or used.
[0033] The above brief description of the packer system 10 is provided for illustrative purposes only and is not limiting upon the present invention. The type, operation, components and arrangement of the packer system 10 are in no way limiting upon the present invention. Further details of the components, arrangement and operation of the packer system 10 , or packer 12 , as well as alternate components and arrangements therefore are, or will be, known to persons skilled in the art and can be found in various patents and printed publications, such as, for example, U.S. Pat. Nos. 6,257,339; 4,862,961; and 4,665,977, each of which is incorporated by reference herein in its entirety. The pressure compensating apparatus 50 of the present invention may be thus used with any suitable equipment and in any suitable environment.
[0034] Now referring to the embodiment of FIG. 2, the pressure compensating apparatus 50 of the present invention includes a piston 54 disposed and movable within a cavity 60 . The piston 54 connects to the mandrel 14 of the packer system 10 and is capable of causing the mandrel 14 to move axially relative to the packer housing 20 coincident with axial movement of the piston 54 in the cavity 60 . In this manner, in accordance with the invention, by placing forces upon the piston 54 , forces may be placed upon the mandrel 14 , and ultimately the shear element 34 .
[0035] Still referring to the exemplary embodiment of FIG. 2, the piston 54 is shown disposed above, or upstream of, the packer system 10 and is threadably engaged with the mandrel 14 . However, the present invention is not limited to such position of the piston 54 or its manner of connection to the mandrel 14 . The illustrated piston 54 has a tubular shape, and the cavity 60 has an annular shape. However, the piston 54 and cavity 60 can have any desired configuration and take any desired shape. Furthermore, the invention may include numerous pistons 54 and/or cavities 60 , as is desired.
[0036] One or more seals 74 , such as a rod seal, may be included to provide a seal proximate to the upper end 61 of the cavity 60 , and one or more seals 78 may be disposed around the piston 54 to seal the cavity 60 proximate to the location of the piston 54 . Seals 74 , 78 are shown as O-ring seals, but may be any suitable sealing component(s).
[0037] The illustrated piston 54 is shown carried by a carrier 64 , which is connected at its upper end to the tubing 40 . The carrier 64 has a central passageway 66 in fluid communication with the axial bore (not shown) of the tubing 40 and the conduit 16 of the mandrel 14 . The piston 54 may be integral to, or connected with, the carrier 64 in any suitable manner as is desired. For example, the carrier 64 may be a piston rod. A piston housing 70 is shown enclosing the piston 54 , carrier 64 , and cavity 60 . In this embodiment, the piston housing 70 is threadably connected to the upper end of the packer housing 20 , but any suitable configuration and form of connection may be used.
[0038] The pressure compensating apparatus 50 is designed to place forces upon the piston 54 by pressurizing the cavity 60 . In the embodiment of FIG. 2, for example, generally downward forces may be placed upon the piston 54 relative to the piston housing 70 , forcing the mandrel 14 downwardly relative to the packer housing 20 . One purpose for such action, for example, is to oppose pressure-induced forces acting generally upwardly upon the mandrel 14 and the resulting mechanical forces on the shear element 34 during use of the packer system 10 .
[0039] In the example of FIG. 2, one or more ports 82 extend through the wall of the piston carrier 64 up-hole of, or above, the piston 54 . The ports 82 allow the communication of pressure to the cavity 60 from the flow passage that includes the central passageway 66 of the carrier 64 , the conduit 16 of the mandrel 14 , and the axial bore (not shown) of the tubing 40 . Thus, in this embodiment, the piston 54 may be loaded through the port(s) 82 on its up-hole side by tubing pressure existing at, or below, the packer system 10 .
[0040] The illustrated embodiment also includes one or more holes 86 extending through the wall of the piston housing 70 and communicating pressure between the borehole 46 above the packer 12 and the cavity 60 below or downhole of the piston 54 . Wellbore pressure is thus ported to the underside of the piston 54 , so as to create a reference pressure in the cavity 60 or to account for differential pressures.
[0041] In FIG. 3, the packer 12 is shown in its set position, as indicated by the elastomeric element 30 being in a “squeezed-out” position. FIG. 4 shows the packer 12 in an emergency release position, the shear element 34 being sheared. However, the differing positions of the packer system 10 , such as shown in FIGS. 1 - 4 are in no way limiting upon the present invention.
[0042] Referring to FIG. 3, if desired, the pressure compensating apparatus 50 may be designed to provide forces (F 2 ) upon the mandrel 14 that precisely, or approximately, offset or compensate for pressure-induced forces (F 1 ) acting upon the mandrel 14 . To accomplish this, the effective piston area (Ap) may be sized to provide force(s) F 2 that are approximately, substantially or precisely, equal to and opposite the force(s) F 1 .
[0043] In the embodiment shown, for example, the pressure compensating apparatus 50 is designed with an effective piston area (Ap) that is equal to the effective mandrel area (Am) acted upon by the tubing pressure. In the equation (F 1 =P 1 ×Am), F 1 represents the pressure-induced forces on the mandrel 14 ; P 1 represents the tubing pressure acting upon the mandrel 14 ; and Am is the effective surface area of the mandrel 14 upon which P 1 acts. (It should be noted that Am includes the effects of ballooning of the tubing and fluid friction). In the equation (F 2 =P 2 ×Ap), F 2 presents the forces acting on the piston 54 that are transferred to the mandrel 14 ; P 2 is the tubing pressure acting on the piston 54 ; and Ap is the effective surface area of the piston 54 (and piston carrier 64 ) upon which P 2 acts. Since P 1 =P 2 in this embodiment, F 2 will equal F 1 if Ap is designed to equal to Am.
[0044] An example comparison of loads placed upon the respective shear elements of a first packer system not equipped according to the present invention and a second packer system used with an embodiment of the present invention is provided below. In this example, which is in no way limiting upon the present invention, the following conditions are presumed:
Coiled tubing outer diameter (CT OD): 2.38 inches (60.5 mm) Coiled tubing inner diameter (CT ID): 2.00 inches (50.8 mm) Packer mandrel outer diameter: 2.375 inches (60.3 mm) True vertical (TV) depth: 10,000 feet (3,048 m) Coiled tubing load at 80% yield: 93,000 pounds (42,185 kg) Packer setting load: 6,000 pounds (2,722 kg) Coiled tubing and annulus pressure 4,300 pounds/square inch before treatment: (302 kg/square cm) Circulation pressure during treatment: 10,000 pounds/square inch (703 kg/square cm) Bottomhole coiled tubing pressure 13,500 pounds/square inch during treatment: (949 kg/square cm) Bottomhole annulus pressure 4,300 pounds/square inch during treatment: (302 kg/square cm) Shear ring and disconnect tolerance: +/−10 percent Coiled tubing hanging weight: ˜40,000 pounds (18,144 kg)
[0045] In the example of the tension-set packer not including the present invention, the operating load on the shear ring during treatment is estimated at 32,000 pounds (14,515 kg). The effective mandrel area Am is 32,000 pounds/(13,500−4,300 pounds/square inch)=3.48 square inches (22.4 square cm). With a minimum 5,000 pound (2,268 kg) margin between operating load and minimum ring shear, the nominal shear rating is 41,000 pounds (18,598 kg) for 10 percent tolerance, and the maximum shear rating is 45,000 pounds (20,412 kg). With such minimum of 5,000 pounds (2,268 kg) separation between maximum ring shear and minimum disconnect load, the minimum nominal load is 55,000 pounds (24,948 kg) for 10 percent tolerance and the maximum disconnect load is 61,000 pounds (27,670 kg). The surface weight to disconnect is 101,000 pounds (45,814 kg) for a hanging weight of 40,000 pounds (18,144 kg), which is 8,000 pounds (3,629 kg) over the conventional maximum allowable coiled tubing load.
[0046] In contrast, in use of the tension-set packer with an embodiment of the pressure compensating apparatus of the present invention having a piston area (Ap) of 3.0 square inches (19.4 square cm), the load on the shear ring during treatment is 5,000 pounds (2,268 kg), that is, (32,000 pounds−((differential pressure, coiled tubing to bottom hole annulus)×Ap)=32,000 pounds−((13,500−4,300) pounds/square inch×3.0 square inches). For the same margins and tolerances as provided above, the maximum required shear rating is 12,000 pounds (5,443 kg). The maximum disconnect load is 20,000 pounds (9,072 kg) and the maximum surface weight to disconnect is 60,000 pounds (27,216 kg). As compared to the above example, the coiled tubing load shear of this example is reduced by approximately 40,000 pounds (18,144 kg). It should be noted that all of the numerical values above are approximations.
[0047] The present invention includes additional features, capabilities, functions, methods, uses and applications that have not been specifically addressed herein but are, or will become, apparent from the description herein, the appended drawings and claims. Preferred embodiments of the present invention thus offer advantages over the prior art and are well adapted to carry out one or more of the objects of the invention.
[0048] It should be understood that the present invention does not require each of the techniques or acts described above. Moreover, the present invention is in no way limited to the above methods of opposing pressure-induced forces upon downhole components. Further, the methods described above and any other methods that may fall within the scope of any of the appended claims can be performed in any desired, suitable particular order and are not necessarily limited to the order described herein or listed in the appended claims. Yet further, the methods of the present invention do not require use of the particular embodiments shown and described in the present specification, such as, for example, the pressure compensating apparatus 50 of FIG. 1, but are equally applicable with any other suitable structure, form and configuration of components.
[0049] Also, it should be understood that the present invention does not require all of the above features and aspects. Any one or more of the above features or aspects may be employed in any suitable configuration without inclusion of other such features or aspects. Further, while preferred embodiments of this invention have been shown and described, many variations, modifications and/or changes of the apparatus and methods of the present invention, such as in the components, details of construction and operation, arrangement of parts and/or methods of use, are possible, contemplated by the applicants, within the scope of the appended claims, and may be made and used by one of ordinary skill in the art without departing from the spirit or teachings of the invention and scope of the appended claims. All matter herein set forth or shown in the accompanying drawings should thus be interpreted as illustrative and not limiting. Accordingly, the scope of the invention and the appended claims is not limited to the embodiments described and shown herein.
|
An apparatus and method for opposing pressure-induced forces acting on a mandrel of a downhole tool. The apparatus and method are particularly suited for use with a packer and include a piston engageable with the mandrel. Forces placed upon the piston by pressure communicated from the tubing bore are transferred to the mandrel.
| 4
|
FILED OF THE INVENTION
The invention relates to a method of processing pictures by matching of picture matching models, and in particular a method which is suitable for recognising pictures, i.e. recognising individual objects in a picture, for the analysis of scenes, in particular for the recognition and assignment of objects, for the control of system components, e.g. avatars, and for picture compression and decompression.
Here, the expression “picture recognition” is taken to have a wide encompassing meaning. In particular, the term “picture recognition” should include the identification of an object in a picture through the comparison with reference pictures and the classification of objects present in a picture.
BACKGROUND OF THE INVENTION
In digital picture processing a range of methods exist which enable the recognition of individual objects in pictures. One example of this is the so-called “template matching” method which looks for an object using a simple copy of an image of the object.
Another method known from technology is the so-called “graph matching” method which is described in the German patent specification DE 4406020.
A method of automated recognition of one or more structures in digitised picture data is also described in the publication DE 19837004.
A disadvantage of the methods known in technology is that simple matching methods which can be carried out with a comparatively moderate amount of computation are less flexible and soon reach their limits, whereas more powerful and more flexible methods are associated with a very high amount of computation.
BRIEF SUMMARY OF THE INVENTION
Accordingly, the object of this invention is to provide a more efficient method for picture processing which can be used with flexibility with simply structured pictures as well as with complex picture scenes.
This object is solved by the method described in Claim 1 .
A method of processing digitised picture data by matching of picture matching models is provided, whereby the method comprises the following steps: (i) provision of a hierarchical structure graph with nodes, which each at least represent a parameterised picture matching model, a specified number of levels arranged above each other, whereby at least one node is present in each level, edges which link pairs of predetermined nodes of different levels and, for each pair of nodes, a father node is defined as the node in the lower level and a son node as the node in the upper level; (ii) application of the structure graph to the picture data, in which, starting with the lowermost level, at least one node is processed, whereby the processing of a node includes the steps: matching of its at least one picture matching model to the picture data by variation of the model parameters, determination of a degree of matching for each parameter variation as a measure for the quality of the picture matching and determination of an assessment for each parameter variation, taking into consideration the at least one determined matching measure, and whereby the assessment determined for each parameter variation is used as the criterion for the processing of a son node of the processed node and, if the criterion is fulfilled, the processing of the son node with the initialisation of its at least one matching model through predetermined parameters of the father node.
A structure graph therefore consists of a quantity of nodes which represent picture matching models and their associated picture matching methods and edges, which each define a pair of father/son nodes and in each case a processing sequence for it.
A significant advantage of the method according to the invention is that, due to the application of a suitably provided structure graph, the method according to the invention enables an efficient combination of highly different picture matching models and associated methods for the processing of digitised picture data. This means that simple picture matching models may be used on the lower levels of the structure graph, enabling initial conclusions to be drawn about the position of objects in the pictures corresponding to the picture data. To this end, methods may be applied which require a comparatively low amount of computation, such as, for example, simple differential imaging methods. Other methods are, for example, based on the assessment of the shape and geometry and the relationship of objects to one another, on colour classifications, template matching, Hough transformations, methods of segmentation (e.g. region-growing approaches), the use of stereo information (e.g. disparity estimation), the extraction and description of textures or the application of neuronal methods for the classification of picture regions.
The matching of a picture matching model occurs through the variation of the parameters of the picture matching model. These parameters include, for example, translation (position), scaling and rotation (orientation) in the picture level, but also local changes in the models.
A rule is also assigned to each picture matching model with which a measure for the quality of the matching of the picture matching model to the picture data to be processed may be determined.
It must be noted that the application of the father/son relationship is only used for the clarification of the processing sequence, but is generally not unambiguous, because not only may each father node possess a number of son nodes, but also each son node may possess a number of father nodes in the structure graph.
With a development of the method according to the invention particularly preferred for the recognition of objects, a structure graph is provided which includes exactly one node in each level, whereby the node represents at least one picture matching model and a lower threshold value and/or an upper threshold value is assigned to specified nodes. In this development the method terminates with the result that no object of the specified object class is recognised if, for a node, the assessment for each parameter variation lies below a lower threshold value assigned to the node, or that at least one object of the specified object class is recognised if, for a node, the assessment of at least one parameter variation lies above the upper threshold value assigned to the node or if the end node is reached.
This development may be applied particularly advantageously in the identification of persons. In comparison to conventional methods it may be operated significantly faster because more efficient evaluation of the picture data may be carried out in that the evaluation starts on a coarse scale on the lowermost level of the structure graph and the parameters found are used for the evaluation of details on higher hierarchical levels, e.g. as initial values for the relevant matching processes.
With another development of the method according to the invention the structure graph, for various orientations and/or arrangements of elements of an object, exhibits at least one node with at least one picture matching model for the orientation to be recognised and specified nodes exhibit an upper and/or lower threshold value for the assessment of the parameter variations. The implementation of the method occurs such that the processing of son nodes of those nodes processed is waived, for which the assessment of each parameter variation lies below the lower threshold value assigned to the relevant node, with the result that the corresponding orientations and/or arrangements of the elements of the object are not present in the picture; that son nodes are processed of those processed nodes for which the assessment for at least one parameter variation lies between the upper and lower assigned threshold values of the relevant node; and that the processing of son nodes is waived for the parameter variations, the assessment of which lies above the assigned upper threshold value of the relevant node, with the result that the orientation and/or arrangement of the elements of the object is classified as present in the picture which receives the best assessment on the highest fully processed level.
This further development is especially advantageous in the recognition of the orientation of an object of an object class in a picture. In particular, this further development may be employed advantageously in estimating poses and differentiating between different poses.
An alternative advantageous further development of the method according to the invention enables the recognition of objects of different object classes and of the arrangement of objects in a picture and may consequently be advantageously employed in scene analysis. Here, the structure graph for each object class comprises at least one node with at least one picture matching model for the object class, whereby specified nodes exhibit a lower and/or upper threshold value for the assessment of the parameter variations. With this further development the processing of son nodes is waived for those nodes for which the assessment of each parameter variation lies below the lower threshold value defined for the relevant node with the result that the associated object is classified as not being present in the picture; son nodes of those processed nodes are processed for which the assessment lies between the lower and upper threshold values for the relevant node for at least one parameter variation; and the processing of son nodes for the parameter variations is waived, the assessment of which lies above the upper threshold value assigned to the relevant node with the result that the associated object is classified as being present in the picture.
A structure graph suitable for a scene analysis is generally a complex formation, whereby for one end node (i.e. a node on the uppermost level of the structure graph) there are typically a number of paths, whereby the term “path” designates a sequence of nodes having a father/son relationship.
This means that there are nodes in the graph which possess more than one father node. This enables single objects to be reused as parts of other complex objects. Consequently, this produces not just a meagre representation of knowledge about objects in structure graphs, but rather the evaluation process profits from it, because the same object parts are no longer in competition with one another in different contexts.
In order to generate a description of a complex scene, a structure graph is used, the paths of which terminate at end nodes, the picture matching models of which represent different types of objects. The lowermost layers in the structure graph contain picture matching models which differentiate between the objects according to size, orientation and coarse structure. In the following layers the objects are subdivided into different classes in order to finally differentiate according to all or a large part of their definite features at the end nodes.
The evaluation process first processes the picture matching models of the lowermost layer using the method assigned to it. Here, the rough positions of the objects are determined. With the decision for a parameter variation of the picture matching models of a node, the method favours initially objects of the corresponding object class with the features defined by the parameter variation. Further evaluation occurs in the next stage with the processing of the picture matching models of the son nodes of the processed node with the best assessment for a parameter variation when the assessment lies above a specified lower and below a specified upper threshold for the node. With this processing stage part of the parameters is used to define the initial values, in particular the position, for the picture matching models and to restrict the possible variations of the parameters of these picture matching models.
The result of the evaluation is a set of parameter variations which belong to objects recognised in the picture. Here, the parameters determine the position and other properties of the picture matching models, such as for example the size.
In a further, particularly advantageous development of the method according to the invention a lower threshold value is assigned to each node of the structure graph and the processing of son nodes of a node is waived if each parameter variation produces an assessment below the threshold value defined for the node.
This means that a few matching stages which look promising are prematurely interrupted, leading to faster execution of the method. If the models employed permit it, the matching dimensions and the assessments are defined such that the assessments of different nodes may be directly compared with one another. In this case in the latter mentioned further development a universal threshold value may be specified for all nodes.
In a preferred further development of the method according to the invention the lower and/or the upper threshold values may be adapted dynamically.
Consequently, the thresholds, for example, due to results for a preceding picture in a sequence may be modified to express a certain expectation regarding the chronological course of the picture sequence, in particular the recognition of the object already detected, in the next picture.
Particularly advantageously, parameters of the processed father nodes may be accepted at least partially in the method according to the invention for the processing of son nodes.
For example, on a lower level of the structure graph the outline of an object may be determined whereupon the corresponding parameters are accepted into the models of the son nodes. The term “accepted” may signify that the parameter values directly enter a matching model without being newly released there for variation, but also that they act as initial values of the matching model or the initial values are calculated from them. The parameters of the father nodes may also be advantageously applied in that they define limits in which appropriate parameters of the picture matching models of the son nodes may be varied. In all of these cases the amount of computation is substantially reduced and, of course, most significantly in the first case.
In an advantageous further development the appropriate assessment of the parameter variations for picture matching models of the father node is taken into account in the assessment of the parameter variations for picture matching models of son nodes. This is particularly of advantage when at the highest processed level in each case different matching processes lead to closely adjacent assessments, involving the risk that, on continuing, the method runs to a sub-optimum solution which does not correspond to the best possible result.
In a further development of the method according to the invention weighting values, which enter into the assessment, are assigned to each picture matching model and/or each edge.
The weighting of the picture matching models and/or of the edges may be practicable when a certain expectation of a picture to be processed is present, and/or when a node encompasses several picture matching models which have different informatory values. When a node exhibits a number of son nodes, the weighting of the edges may also be applied to specify a processing sequence of the son nodes, which, with a suitable selection of threshold values (interruption criteria), may help to avoid a superfluous amount of computation. Also, combinations which offer more information or are more plausible of different nodes may reasonably be taken into account, because these weighting factors may act as a predetermined measure of which combination of picture matching models of nodes on different levels is attributed a particularly high level of informatory value.
With a particularly preferred further development of all previously mentioned methods, the picture matching models of the nodes of the uppermost level are based on digitised reference picture data and/or the picture matching models of predetermined nodes are based on the picture matching models of their son nodes.
This means that in a simple manner a hierarchy in the complexity of the picture matching models may be achieved, whereby for example the picture matching models of the end nodes correspond to detailed portraits, whereas picture matching models are built up more simply, i.e. for example, they exhibit fewer parameters the deeper the level is located. Such simplified picture matching models may be quickly adapted, whereby a quick and effective evaluation is ensured in the lower levels, which in turn has a positive effect on the overall efficiency of the method.
With particular preference, the picture matching models of the nodes of the structure graph encompass graphs of features, so-called model graphs, which consist of a two-dimensional arrangement of model graph nodes and edges. Here, features which contain information about picture data are assigned to the model graph nodes. The model graph edges code the relative arrangement of the model graph nodes.
Particularly preferred model graphs are so-called reference graphs, the features of which are the results of the application of a set of filters, e.g. Gabor filters, on the digitised data of comparative pictures. Here, the features may be the results of the application of a set of filters to picture data which itself may originate from different comparative pictures.
The set of filters may be obtained using scaling and rotation from an original filter. The scaling of the filters, from which the features are obtained, is preferably smaller from hierarchical stage to hierarchical stage, whereby the frequency increases or the resolution becomes more refined. These types of feature are termed jets.
With the matching of the picture matching model graphs the similarity of the jets of each picture matching model graph node k is calculated with the corresponding jets of the current picture. In addition, a number of features m, which may be generated from different pictures or a previous learning process for the picture matching model features, may be assigned to each picture matching model graph node. For each picture matching model graph node the similarity of its jet to the jet from the current picture is calculated for a certain position. In this respect, the jets of each reference graph j (k,m) are compared to the jets from the current picture {tilde over (j)} (k).
In the most general case a descriptive measure of matching is produced for the parameter variations of the picture matching models for the overall similarity between the picture matching model graph and the picture according to the formula:
S (n) =f (n) ( P k (n) j ( k,m ), P k (n) {tilde over (j)} ( k ), d (0) ( k,m ), d (n) ( k,m )), k εK′ ( n ) ⊂ K,
whereby
j (k,m) is the jet of the picture matching model m on the node k,
{tilde over (j)} (k) is the jet of the picture on the position of the node k,
d (0) (k,m) is the original position of the node k of the picture matching model m,
d (n) (k,m) is the position of the node k of the picture matching model m in step n,
f (n) ( . . . ) is a functional of the picture matching model jet and the picture jet at corresponding locations,
P k (n) represents an image of the jet j (k,m) or {tilde over (j)} (k), and
K′(n) is a subset of the set K of all graph nodes k.
The original position and its change is used for the computation of the topological costs incurred by too strong a deformation of the picture matching model. The step parameter n here indicates that the computation of the overall similarity varies both during the individual phases of the matching process for a picture matching model and also for picture matching model to picture matching model. In particular, the matching process is subdivided into a number of phases, such as for example the coarse positioning, resealing and fine matching of the picture matching model. In each phase the overall similarity is calculated in an adequate manner.
In a preferred form the similarity of the graph is chosen in step n as:
S (n) =f 2 (n) ( k,f 1 (n) ( n,s ( P k (n) j ( k,m ), P k (n) {tilde over (j)} ( k )), d (0) ( k,m ), d (n) ( k,m )))
Here f 1 (n) (n,s(P k (n) j (k,m),P k (n) {tilde over (j)} (k)), d (0) (k,m), d (n) (k,m)) is the similarity of the picture jet to the picture matching model jets or the submodel jets for step n.
Via f 2 (n) (k, . . . ) an overall measure is obtained over all nodes. In this connection topological costs may in particular be taken into account. These form a measure of the local deformation of the model graph which arises during the matching through the displacement of the model graph nodes with respect to one another.
In further preferred forms a summation, weighted summation or mean formation is chosen both for f 1 as well as for f 2 . (With f 1 as the sum over the picture matching models or picture matching model subjets, with f 2 as the sum over the nodes.)
In other constellations it has also proven to be advantageous to use an ordering operation such as the median or the “trimmed mean” for f 1 or f 2 .
In a particularly preferred form the jet similarity of the graph may be chosen in step n as:
S
(
n
)
=
∑
k
∈
K
′
(
n
)
l
m
th
(
n
)
s
(
P
k
(
n
)
j
_
(
k
,
m
)
,
P
k
(
n
)
j
~
_
(
k
)
)
+
f
(
n
)
(
d
_
(
0
)
(
k
,
m
)
,
d
_
(
n
)
(
k
,
m
)
)
Here l m th (n) designates an ordering operation on the m jet similarities s(P (n) j (k,m),P (n) {tilde over (j)} (k)), e.g. with l=1 the maximum of the m similarities.
The changes in the topology of the picture matching models are taken into account with f (n) ( d (0) (k,m), d (n) (k,m)).
In a further indicated form P (n) is a function of jets which transforms the vector j into a vector j′, whereby the components of j ′ are a subset of the components of j . This function may however vary over the nodes. This is particularly of benefit if the approximate position of the model on the picture region is to be found through the selection of the low frequency portions on a node, while at the same time high frequency portions are used on other significant nodes to increase the sensitivity of the localisation and detection resolution.
If the jets are represented in the form of amplitudes (a i ) and phases (p i ), then the feature similarity s( j , {tilde over (j)} ) may be calculated in preferred embodiments according to one of the following formulas:
s
(
j
_
,
j
_
~
)
=
∑
i
a
i
(
m
)
a
~
i
∑
i
a
i
(
m
)
a
i
(
m
)
∑
i
a
i
~
a
~
i
s
(
j
_
,
j
~
_
)
=
∑
i
a
i
(
m
)
a
~
i
cos
(
p
i
(
m
)
-
p
~
i
)
∑
i
a
i
(
m
)
a
i
(
m
)
∑
i
a
~
i
a
~
i
s
(
j
_
,
j
~
_
)
=
∑
i
a
i
(
m
)
a
~
i
cos
(
p
i
(
m
)
-
p
~
i
-
dk
_
i
)
∑
i
a
i
(
m
)
a
i
(
m
)
∑
i
a
~
i
a
~
i
.
In the last formula d designates the disparity between the model and picture jets. To determine s, d is varied such that s is a maximum. k designates here the position of the i-th filter in the Fourier space.
In a further preferred form, the vectors on the nodes may not just represent jets in the conventional sense, which are based on a Gabor transformation, but rather also so-called compound jets, the components of which also represent non-homogeneous representations of a region, e.g. edge information in a component and similarity to a colour in another.
Furthermore the combination of a number of these methods (i.e. of the picture matching model associated with the methods) within a node of the structure graph is practicable, because the results of the individual methods in the computation of an overall assessment (i.e. quality of matching) for the node permits a more exact assessment of the picture data used as a basis than would be the case with each method taken alone.
A special form of the method described here is the bunch graph matching which may be represented as:
S
=
∑
k
∈
K
max
m
s
(
j
_
(
k
,
m
)
,
j
_
~
(
k
)
)
In a possible embodiment the picture matching models on the nodes each possess a set of the same features, so-called bundled jets. This bundle generally represents a special aspect of an object as a set of features obtained from a set of individual characteristics. If such a picture matching model represents a face, then the right eye, left eye, mouth and nose are special aspects. They are each represented by a set of features obtained from the corresponding aspects of a set of comparative pictures, which each show the face of another person with possibly another facial expression.
The number of features needed to cover a representative part of the different characteristics and therefore to obtain a sufficiently general representation of the aspect varies. This is on one hand the case from node to node of the picture matching model, because the object generally has simple aspects which are very similar for all individuals, and at the same time has other more complex aspects which differ significantly from individual to individual.
With the application of filters of different sizes the dependence of the resolution is also included. Consequently, generally a few representatives are sufficient for the features obtained from the coarse filters, whereas the same aspects for the features of the fine resolving filters vary more significantly and therefore more features of different individuals are needed in order to achieve the same general validity of the representation than is the case for the coarsely resolving filters and their features. The number of features in the bundles of the picture matching model nodes reduces accordingly when the resolution of the filters is reduced from the end nodes towards the start node.
The classical representation with only one picture matching model cannot profit from this fact, because the features include all filters from coarse to fine resolution.
Preferably the structure graph is set up such that the features include combinations of different types of jets. With regard to the evaluation of the structure graph, it is practicable if the individuals, from which the features are obtained and which contribute to the optimum matching of a picture matching model on a level, change from level to level.
This enables a very compact representation through the structure graph, because with the classical graph matching, features are always needed which contain all the applied filters with their various resolutions. In this respect a bundle would need in each case to contain an appropriate feature for all possible combinations of the features for the individual resolutions in order to achieve the same generality as the described representation via the structure graph. Apart from the management of the very large number of features, which are needed according to the laws on combination theory, the procurement of the data for all these individuals renders this approach very cumbersome, if not unusable.
The described method is very suitable in a further development for picture compression and decompression.
Picture compression comprises the steps: compression of each recognised object with a given compression factor for the appropriate object class, whereby the control of the parameters of the compression method is based on the parameters from the results of the scene analysis and compression of the picture region (background) not occupied by objects using a higher given compression factor.
During the compression the picture is segmented into single objects according to the above described scene analysis. These objects have here already been broken down into their constituent parts by the picture matching model along the associated path in the structure graph. The information from the segmentation and the breaking down of the objects may be used for the compression in many ways:
Through the control of the parameters of a conventional compression method, it is ensured that the “interesting” objects may be reproduced with good quality after the decompression, whereas the “uninteresting” regions of the picture are more substantially compressed, whereby the losses in quality resulting from this are not a disturbance in the reproduction. If the structure graph is available during the decompression, then an identifier for the path in the structure graph which has been found for an object may be transferred. During the decompression a type of phantom object may then be generated based on the knowledge via the path in the structure graph. In addition, the information may be coded which enables the phantom object to adapt to the actual object. In this way only a very compact code for the object class (the path in the structure graph) and the information about the variation of the actual object compared to its class representative need to be transferred. Instead of retaining the complete structure graph for the decompression, the relevant part may be initially coded. During the compression of picture sequences, the part of the structure graph needed for an object only needs to be transferred once and then the appropriate part may be coded again by a short identifier.
The picture decompression of this sort of compressed picture occurs by the reverse of the procedure used for the compression.
As already described under picture compression/decompression, the information obtained about the picture content may also be used in order to replace the actual objects in the picture by the representatives of their object class.
The preferred development of the appropriate method includes the steps: provision of reference pictures of the object representatives, substitution of the at least one selected recognised object by the object representative, whereby part of the parameters of the picture matching models may be applied to the control of the object representatives.
This technique may also be applied to use any placeholders, so-called avatars, instead of the representatives. These avatars may be controlled through the processing of picture sequences and the tracking of objects which it produces and their intrinsic movements. This technique is used in video telephony, 3D internet chat, in trick-film techniques and in the control of virtual figures of interactive software, such as for example a game or a virtual museum.
Similarly, advantageous further developments of the method according to the invention may be used to replace the background in a picture by a different background in that at least one reference picture is provided for the other background and then at least one object recognised by the method according to the invention is inserted into the reference picture.
Here, combinations of the latter mentioned methods are also possible so that—starting from a real picture with object(s) and background—an artificial picture is created, whereby at least one of these objects is replaced by an object representative and the background by a different background.
In order to be able to visualise such pictures more easily without in each case having to process, save or transfer the entire information, a preferred further development of the method according to the invention makes available a data base with the object representatives and/or the reference pictures for the background. In particular for the transfer of such processed pictures, it proves useful if the data base is also made available on the receiver side.
In particular, a further development is suitable for all types of trick-film techniques, in which the object representatives include real objects and/or virtual objects.
This enables almost any desired scenes to be composed.
A particularly advantageous further development of the method according to the invention may be used for processing the individual pictures of a picture sequence. To do this, the parameters of the picture matching models are allocated initial values which use part of the parameters from the processing of previous pictures.
In comparison to the processing of individual pictures carried out independently from one another, a substantial speeding up of the processing procedure may be achieved in this way.
Preferably, the possible variations of the parameters of the picture matching models based on a part of the parameters from the processing of previous pictures are restricted, because in this way the number of the computation operations to be carried out may be further restricted. This is mainly practicable when chronologically sequential pictures of a picture scene which changes relatively little are to be processed.
In the following particular embodiments of the invention are explained with reference to the accompanying figures, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 : shows a preferred method of object recognition,
FIG. 2 : shows a preferred method of estimating a pose,
FIGS. 3 A/ 3 B: show picture matching models used for a picture analysis on different hierarchical levels,
FIGS. 4 A/ 4 B: show a picture analysis carried out with the picture matching models illustrated in FIGS. 3 A/ 3 B.
DETAILED DESCRIPTION OF THE INVENTION
Object Recognition
In this embodiment the structure graph consists of a chain of nodes, each of which is connected by aligned edges.
The object of the evaluation process here is the efficient selection of suitable parameters for all picture matching models in the structure graph. This includes in particular the position of the object in the picture.
In a particularly effective embodiment the picture matching models of the nodes represent picture information, the degree of detail of which increases from level to level in the direction of the end node. The degree of detail may here vary both in the complexity of the picture matching model and/or in the resolution of the representation of the picture data.
In order, for example, to be able to recognise a person in a picture completely with body, head, arms and legs, a structure graph is provided which in the node on the lowermost level exhibits a very simple picture matching model which has just sufficient information about the picture data to acquire the rough alignment of a person as a whole. At the next higher levels the corresponding picture matching model encompasses increasingly more details and the applied representation of the picture data enables these still relatively coarse structures to be recognised if they are present in the picture to be examined.
The evaluation process starts on the node of the lowest level whose picture matching model is matched to the picture data, whereby the parameters of the picture matching model, in particular the parameters for the positioning of the model, are varied until the best possible (or at least a sufficiently good) match, i.e. exceeding a given threshold value, is achieved with the current picture data. The resulting parameter set describes the rough alignment of the person in the picture.
With the transition to the son node of the processed node, the associated picture matching model is preassigned with suitable parameters (parameter initialisation), whereby the parameter values resulting from the variation methods carried out for the processed node are taken into account. This includes particularly the definition of the position and the choice of a suitable variation range for the position.
The matching process refines the position of the object and determines suitable parameters for the additional degrees of freedom which highlight this picture matching model from the previous one. The same procedure is used with the other nodes on the path to the end node and for the end node itself.
At the end of the evaluation process all nodes of the chain are processed and the picture matching model assigned to them matched to the picture data. Here, the complete information about the object, such as for example the position and type of individual parts, may be distributed over the whole of the picture matching models and their parameter assignments.
FIG. 1 clearly shows a preferred embodiment of the method according to the invention for object recognition.
The reference symbols 1 , 2 , 3 stand for the nodes of the structure graph which consists of a simple chain of three nodes in this example. The “node” 0 is not part of the actual structure graph, but instead stands symbolically for the initialisation of the method procedure.
Since with this simple embodiment, one node and the associated level may be identified together, the same reference symbols are used for the node and associated level.
For reasons of better clarity, the picture matching models and stages corresponding to a node in the drawing level are illustrated in each case above the symbol representing the node.
This means that node 1 is processed in step 0 → 1 and correspondingly node 2 in step 1 → 2 and node 3 in step 2 → 3 .
The left partial picture shows here in each case the matching model before the matching process and the right partial picture shows the matching model after the matching process.
The left partial picture of the first level 1 has been initialised with any parameters. In contrast, the corresponding left partial pictures on levels 2 and 3 have been initialised with the parameters in each case of the right partial picture of the upper adjacent level.
It must be noted that in FIG. 1 —as also in the corresponding following figures—the hierarchical stages increase from the top to the bottom.
The evaluation method begins with node 1 : The picture matching model of this node is a very coarse model of faces which essentially represents the outline of the face. The picture information is also represented very coarsely, e.g. with low-frequency filters for only two different directions. During the matching process, this model is evaluated at all possible picture points or an adequately selected subset, for example by sampling down, before the best parameter variation for the processing of the following levels is applied. Due to the coarse view of the picture, the matching process is carried out on a coarse pitch so that only relatively few possibilities need to be evaluated. The assessment of the individual possibilities also occurs very fast, because the picture information is represented with only a few filters.
Once the matching process on the lowermost level is concluded, the model of node 2 is initialised based on the results of the father node 1 . Here, in particular the localisation of the model is accepted, i.e. the parameters of node 1 describing the positioning are taken into account for its son node 2 .
The matching process of the matching model of node 2 only operates on a small picture extract and essentially carries out local optimisations of the results of the first level. With this optimisation the now additional available information of the refined model and the more accurate representation of the picture is exploited through more and better resolved filters.
After the matching of this model the model of node 3 is accordingly initialised. The relatively complicated matching of this model now occurs only within a very restricted search space and is therefore quickly concluded.
The advantages of the method compared to the conventional graph matching and its variants lie in the refined control of the overall matching process due to the structure graphs.
The situation is avoided where detailed model and picture information must be taken into account for matching the coarse structure; at this stage they would not contribute to any relevant gain of information, but would drastically increase the amount of computation. Through application of the structure graph, details are only taken into account (at higher hierarchical levels of the structure graphs) when this is practicable.
With conventional (classical) graph matching, the consistent application of detailed picture information and complex models also often leads to suboptimum solutions. This disadvantage can also be avoided by the method according to the invention by applying the structure graphs.
Pose Estimation
FIG. 2 shows an embodiment of the method according to the invention which may in particular be used for pose estimation.
With this embodiment the associated structure graph exhibits a similarity to a tree with branches.
For each parameter variation an assessment is computed which arises from the matching dimensions of the picture matching models of a node and the weightings assigned to them.
The evaluation process is continued with the son nodes of the node for which the best assessment of a parameter variation has been attained. The picture matching models of the son nodes of this node are preassigned with suitable parameters. This particularly includes the positioning of the picture matching model in the current picture.
All previously assessed parameter variations are in competition. Therefore the evaluation may be continued at a node different from one of the son nodes of the currently considered node. This always takes place when the assessments for all parameter variations of the currently considered node are worse than a previously assessed parameter variation. This procedure enables the structure graph to be evaluated without having to make a decision prematurely which would then possibly lead to a worse or even incorrect result.
As already seen with the first example ( FIG. 1 ), the “start node” 0 is not an integral constituent part of the structure graph, but rather is only used for the initialisation of the method. Using this node, it may be specified, for example, in which sequence the nodes 1 , 2 , 3 of the lowermost level of the structure graph are to be processed.
In the structure graph a subdivision into simple structures occurs on the lowermost level 1 . With increasing hierarchical stages the structures become more and more complex until they possess the full complexity for the representation of complete objects at the end nodes, the nodes of level 3 .
In order to be able to recognise the head of a person in the picture in a wide spectrum of different poses or head postures, a structure graph is formed in which the picture matching models in the lowermost level 1 only represent the coarse head shape from rounded to elongated and coarse orientation in the plane of the picture.
The models of the next (second lowest in the hierarchy) level 2 represent the head shape and a coarse form of the inner structure of faces, such as for example the position of the eye recesses and the mouth region.
Level 3 is the uppermost level of the structure graph and exhibits end nodes, the models of which encompass the complete representation of the faces in various poses.
Matching of the models of the nodes of the lowest level occurs as described in the last example and supplies the assessments given in the picture, whereby in each case only the assessment for the best parameter variation is given. They are the assessment 0.9 for the node 1 processed in step 0 → 1 , assessment 0.8 for the node 2 processed in step 0 → 2 and the assessment 0.7 for the node 3 processed in step 0 → 3 .
Based on these assessments the son nodes of node 1 , situated on the second level of the structure graph, are now processed first, whereby their picture matching models are initialised based on the results of the matching process for node 1 .
After processing the son nodes 4 , 5 , 6 of node 1 , the assessments of 0.7 for node 4 , 0.75 for node 5 and 0.6 for node 6 result.
These assessments are however worse than the assessment of the node processed on the first level in step 0 → 2 , the assessment of which is 0.8.
Further evaluation of the paths starting with step 0 → 1 is therefore initially withdrawn and first the possible promising processing of the son nodes of node 2 processed in step 0 → 2 is carried out.
In this respect, the models of the son nodes based on the matching of the model of node 2 processed in step 0 → 2 are initialised and then the matching method is again carried out.
For nodes 7 , 8 , 9 the matching leads to the assessments 0.65, 0.6 and 0.5 given in the picture. Therefore, the best assessment of the son nodes 7 , 8 , 9 of the node 2 lies below the best assessment of a son node of node 1 processed in step {circle around ( 0 )}→{circle around ( 1 )}.
Consequently, processing of the son nodes of the best assessed node 5 of the second level now proceeds. These are the nodes 10 - 12 .
The matching of the associated models supplies the best assessment for node 11 which with 0.74 is also higher than the best assessment of nodes 7 - 9 of the hierarchical level 2 situated below.
The evaluation of the structure graph can therefore be concluded.
Scene Analysis
Since scenes may have any degree of complexity, a structure graph which may be used for scene analysis is generally a very complex formation, whereby there are typically many paths to the end nodes. This means that there may be nodes in the graph which possess more than one father node. This enables single objects to be reused as parts of other complex objects. Consequently, it is not just a meagre representation of the knowledge about objects in structure graphs which arises, but rather the evaluation process profits from it, because the same object parts no longer compete with one another in different contexts.
This type of scene analysis is now described in the following with reference to FIGS. 3A , 3 B and 4 A, 4 B.
In order to generate a description of a complex scene, a structure graph is used whose paths end at end nodes whose models represent different types of objects.
The lowermost level of such a structure graph contains models which differentiate the objects according to size, orientation and coarse structure. In the higher levels the objects are subdivided into various object classes so that at the end nodes differentiation may take place according to all or a large part of their established characteristics.
FIGS. 3 A/ 3 B illustrate picture matching models 100 , 200 , 300 ; 110 ; 210 , 310 , 320 , 330 , 340 ; 111 , 211 , 321 , 341 used for a picture analysis on three different hierarchical levels 1 ; . . . ; i . . . ; i+j, . . . ( 1 <i<i+j).
FIGS. 4 A/ 4 B show a picture analysis which was carried out on a complex scene with the picture matching models illustrated in FIGS. 3 A/ 3 B.
As the upper partial picture of FIG. 4A shows, the evaluation process first processes the models 100 , 200 , 300 of the lowermost level 1 with the methods assigned to them. Here, the objects are classified according to their orientation or preferred direction and their rough position in the picture is determined. For the man shown in the upper partial picture of FIG. 4A , model 100 fits, for the tree model 200 fits and model 300 is the best both for the car and also for the house. With the decision for a node, the method favours initially objects of the appropriate size and coarse structure of the models of this node.
Further evaluation occurs again through the processing of the models of all son nodes with the method assigned to them. The selection of the next node occurs again from the nodes at which the previously assessed paths terminate. The evaluation however does not terminate with the determination of the first complete path, i.e. a path leading to an end node, but rather is continued until the assessment of the remaining paths appears to be uninteresting with regard to further evaluation. The result of this evaluation therefore consists of a set of complete paths through the structure graph, whereby each complete path belongs to an object in the picture. The set of these paths therefore corresponds to a description of the picture as a set of objects and their arrangement.
|
A method of processing digitized picture data includes providing an hierarchical structure graph which is applied to the picture data in that, starting with the lowermost level, at least one node is processed. The provided hierarchical structure graph includes nodes, a specified number of levels, with at least one node located in each level, and edges connecting pairs of predetermined nodes of different levels and defining, for each pair of nodes, a lower father node and an upper son node. Processing of a node includes matching of its at least one picture matching model to the picture data by variation of the model parameters, determination of a matching quantity for each parameter variation, and determination of an assessment for each parameter variation. The assessment found for each parameter variation is applied as a criterion for the processing of a son node of the processed node.
| 6
|
BACKGROUND
The present invention relates to a multi-part closure device such as an ice pack clip for releasably sealing ice packs and similar flexible open-ended containers.
It is known to seal ice packs used for a variety of purposes with ice pack clips which are generally of the blade and trough (or sheath) type. The known devices generally include a hinge at one end connecting the blade and the trough and a latch at the other end for releasably closing the clip to seal a bag which passes between the trough and the blade when the clip is closed. Similar clips or clamps are also suitable for a variety of other purposes, including ostomy bags, umbilical cord clamps, etc.
Depending upon the type of clip or clamp chosen, there are shortcomings. For instance, some clips presently used with ice packs consist of a one-piece construction having a blade portion and a trough portion pivotally connected by a hinge. This construction is not easily adapted to automated sorting and feeding. Due to the inherent flexibility of the hinge, the blade and trough move with respect to one another when the clip is subjected to the vibrations often encountered during automated mechanical sorting processes. This movement makes automated feeding difficult. As a result, currently it is required that these clips be attached to ice packs manually resulting in limited production capacity and requiring human participation in the assembly process.
As such, there exists a need for a clip suitable for use on ice packs, ostomy bags, umbilical cord clamps, etc. that exhibits all the advantages of the presently used clip but lends itself to automated sorting, feeding, and assembly.
SUMMARY OF THE INVENTION
As such, one aspect of the present invention discloses a multi-part closure device including a substantially planar blade and a trough. Each piece has a latch end and a connector end. The trough has a necked portion proximal to the trough connector end. Each of the connector ends are fastened one to the other so as to create a rigid joint between the blade and the trough. This enables the necked portion to form a hinge which in turn enables the trough to hinge at the necked portion. Hinging is accomplished substantially about one axis while the blade and rigid joint remain stationary with respect to the trough.
Another aspect of the present invention provides a multi-part closure device or clip having a first and a second clip body component. The clip also has a releasable latch at one end, a rigid connection at an opposite end, and at least one flexible neck disposed between the releasable latch and the rigid connection. The flexible neck hinges one clip body component with respect to the other clip body component while enabling the rigid connection to remain stationary.
Another aspect of the present invention provides a multi-part closure device having a first and a second clip body component each having a connecting portion. A flexible neck is disposed upon at least one of the clip body components proximate to the connecting portion. The flexible neck forms a hinge between the first and second clip body components when the first and second connecting portions are secured one to the other. The first and second connecting portions serve to rigidly connect the two clip body components one to the other at a rigid connection while allowing each clip body component having a flexible neck disposed thereon to move with respect to the other clip body component and the rigid connection.
Still another aspect of the present invention provides a multi-part closure device having a first and second clip body component. The second clip body component is securely fastened to the first clip body component at a rigid connection. At least one flexible region is disposed proximate to the rigid connection. The flexible region serves to enable at least one clip body component to hinge with respect to the rigid connection.
In yet another aspect of the present invention a multi-part closure device is disclosed. The device includes a first and a second clip body component. Each clip body component terminates in a releasable latch end and a rigid connection end. A flexible neck is disposed upon at least one clip body component proximal to the rigid connection end. The flexible neck enables the clip body component upon which it is disposed to hinge about the flexible neck and move with respect to the rigid connection end.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of an open clip of the prior art design.
FIG. 2 is a side view in partial cutaway of the FIG. 1 prior art design.
FIG. 3 is a side view of an open clip of the present invention.
FIG. 4 shows an embodiment of the rigid connection end of the clip of the present invention.
FIG. 5 shows an alternative embodiment of the rigid connection end of the clip of the present invention.
FIG. 6 is a side view of an alternative embodiment of the FIG. 3 open clip of the present invention.
FIG. 7 is a side view of an alternative embodiment of the FIG. 3 open clip of the present invention.
DESCRIPTION OF THE INVENTION
The present invention and its advantages are best understood by referring to the drawings, like numerals being used for like and corresponding parts of the various drawings.
Prior art FIGS. 1 and 2 show a clip 10 which in pertinent part is formed of four major components, a substantially planar blade 12 , a trough 14 , a hinge 16 , and a latching mechanism 18 . The blade 12 is designed to fit within the trough 14 such that when a bag (not shown) is interposed between the closed blade 12 and the trough 14 , the blade 12 and trough 14 cooperate to effectively seal the bag. The blade 12 and trough 14 are designed to be manufactured as a single unit and remain connected via the hinge 16 . The hinge commonly used is preferably a strap-like hinge, known in the art as a “living hinge”. The present invention eliminates this living hinge 16 and substitutes a new configuration.
In the present invention, shown in FIG. 3 , a new clip 20 is depicted. The clip 20 is manufactured as two separate components or clip body components 22 and 24 . The clip body components 22 and 24 may be configured similarly to the trough and hinge arrangement disclosed in U.S. Pat. No. 5,604,959, which is fully incorporated herein by reference. However, in the present invention, it is not until the two portions 22 , 24 are attached one to the other, that the clip 20 itself is ultimately formed.
Looking to FIG. 3 , it can be seen that each clip body component 22 , 24 is provided with a portion of a latch or latching mechanism 26 and a blade connector end, also referred to as a connecting end, or connecting portion 28 . The specific design of the latching mechanism 26 is not critical to the invention and therefore the mechanism 26 may be configured similar to that disclosed in U.S. Pat. No. 5,604,959.
Proximate to the connecting portion 28 of at least one of the clip body components 22 , 24 is a necked portion or necked region 30 . The necked region 30 is sufficiently thin and flexible enough to enable the clip body component 22 or 24 upon which it is located to hinge at the necked region 30 once the clip 20 is assembled. As shown in FIG. 3 , this necked region 30 effectively allows the clip 20 to open and close enabling movement between a latched and an unlatched position. Formation of the clip 20 is accomplished when the connecting portions 28 of each clip body component 22 and 24 are fastened in some manner to one another resulting in the creation of a rigid configuration or connection 32 .
To better enable the necked region 30 to hinge properly at the rigid connection 32 , the components 22 and 24 may be constructed so as to possess added thickness and rigidity at the connecting portions 28 . Further, the necked region 30 may be made sufficiently thin so as to flexibly hinge between the connecting portion 28 and the remainder of the clip body component 22 and/or 24 . This arrangement moves the latching mechanism 28 toward and away from a clip open and a clip closed position allowing a bag (not shown) to be captured between the clip body components 22 and 24 .
More specifically, the necked region 30 permits the clip body component 22 having the necked region to hinge with respect to the other clip body component and the rigid connection 32 . Although the necked region 30 is depicted as being on clip body component 22 , it may alternatively be located on clip body component 24 as depicted in FIG. 6 . Other embodiments, such as that depicted in FIG. 7 , may include providing at least one necked region 30 on each clip body component 22 and 24 . This would enable both clip body components 22 and 24 to hinge with respect to each other while the rigid connection 32 remained stationary.
A number of possible alternatives are available to fasten the clip body components 22 and 24 together. In the FIG. 4 embodiment, two surfaces, 34 and 36 are depicted, one at each of the connecting portions 28 . These surfaces when joined together form the rigid connection 32 . The rigid connection 32 can be made permanent via the application of adhesives, through the use of thermal and/or ultrasonic bonding, etc. It is well known in the art that a typical bond may be configured so as to include raised features (not shown) in order to create a bond concentration. Alignment nibs 38 depicted in the FIG. 4 may also be provided on either or both connecting portions 28 to assist in alignment of the clip body components 22 , 24 . Alignment nibs 38 may take any number of forms including raised areas and complementary recessed areas and be located on either or both of the surfaces 34 and/or 36 .
One possible alternative, as shown for example in FIG. 5 , provides fasteners 40 which serve to fasten the clip body components 22 and 24 one to the other. Examples of such fasteners 40 may include bayonet-type fasteners as shown having a male portion 42 and a female portion 44 , however, post and post aperture arrangements, single and multiple tab and slot arrangements, as well as other male/female type fittings are suitable as well. In general, it is desirable to design the fasteners 40 so that more force is required to separate the connecting portions 28 than is required to unlatch the latch mechanism 26 . As such, in some embodiments, the fasteners 40 may be semi-permanently joined. In other embodiments, the fasteners 40 may be permanently joined. Likewise, it should be apparent that it is also desirable to design the fasteners 40 to have sufficient strength to entrap and seal a bag or other material, such as an ice pack, between the body components 22 and 24 so that the material does not leak fluid therefrom.
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.
|
The invention relates to a multi-part closure device or clip having a first and a second clip body component. The clip has a releasable latch at one end, a rigid connection at an opposite end, and at least one flexible neck disposed between the releasable latch and the rigid connection. The flexible neck hinges one clip body component with respect to the other clip body component while enabling the rigid connection to remain stationary with respect to both clip body components.
| 1
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is the U.S. National Phase application of PCT Application No. PCT/CN2014/080240 filed on Jun. 18, 2014, which claims priority to Chinese Application No. 201310241902.X filed on Jun. 18, 2013, the contents of each of which are incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to a vehicle component, and more particularly to a vehicle energy absorbing device.
BACKGROUND
As the automobile industry continuously develops and the consumption market becomes increasingly mature, people attach more and more importance to vehicle crash safety. On the one hand, unreasonable deformation occurring in crash will lead to a reduction of a living space in the occupant compartment, thereby severely threatening the safety of occupants, and current vehicle anti-crash energy absorbing devices are mainly designed for that purpose. On the other hand, people's attention is not only confined to the safety of occupants in a vehicle, but also extended to that of pedestrians in a car crash. If a car collides with a pedestrian, the car body is often in direct contact with the legs of the pedestrian, thereby causing damages to the legs. Current vehicle anti-crash energy absorbing devices designed for the sake of occupant safety can hardly satisfy the requirement of the national standard GB/T24550-2009. The patent application No. 201120557659.9 provides a bumper beam of a vehicle bumper designed for protecting lower legs of pedestrians, which comprises a first-stage energy absorbing area and a second-stage energy absorbing area that are adjacent to each other; however, the energy absorbing devices cannot meet the requirement of GB 17354 for low-speed car crashes. Current energy absorbing devices designed for the sake of pedestrian safety all fail to satisfy the above two requirements simultaneously, so it is urgent to have a vehicle energy absorbing device that can not only decrease harms to lower legs of pedestrians, but also reduce damages to automobiles as a result of low-speed crash.
SUMMARY OF THE INVENTION
To solve the problems in the prior art, the present invention is intended to provide a vehicle energy absorbing device that can not only decrease harms to lower legs of pedestrians, but also reduce damages to automobiles as a result of low-speed crash, so as to meet the requirements of relevant rules and regulations.
The vehicle energy absorbing device according to the present invention comprises a primary energy absorbing box and a secondary energy absorbing box, said primary energy absorbing box having a U-shaped cross section with a bottom and walls extending therefrom, said secondary energy absorbing box being nested inside said primary energy absorbing box.
By means of the above technical solution, the present invention is able to achieve that in the crash of a car with a pedestrian, said secondary energy absorbing box can provide continuous stiffness when said primary energy absorbing box is nearly collapsed, so as to protect lower legs of pedestrians and reduce harms to legs of pedestrians. The vehicle energy absorbing device of the present invention can meet the requirements of both GB/T24550-2009 and GB 17354. It can not only decrease harms to lower legs of pedestrians, but also reduce damages to automobiles as a result of low-speed crash.
In an embodiment, said energy absorbing device further comprises a bumper system with a front bumper beam, and an overlap between said primary energy absorbing box and said front bumper beam is more than 80%.
In an embodiment, the nesting amount of said secondary energy absorbing box is less than 10% of the depth of said primary energy absorbing box.
In an embodiment, said energy absorbing device further comprises a skin, said secondary energy absorbing box being integrated onto said skin.
In an embodiment, said energy absorbing device further comprises a lower grid and an upper grid, said primary energy absorbing box being fixed to said lower grid and said upper grid.
In an embodiment, said primary energy absorbing box has an U upper end snap structure which cooperates with an energy absorbing box mounting structure of said upper grid and an U lower end snap structure which cooperates with an energy absorbing box mounting structure of said lower grid.
In an embodiment, said primary energy absorbing box is injection molded from polypropylene, EPDM rubber, and 10% talc modified material.
In an embodiment, reinforcing rib structures are uniformly distributed within said primary energy absorbing box at a location corresponding to said bottom.
Preferably, said reinforcing rib structures have a height of 10 mm and a wall thickness of 2.5 mm.
In an embodiment, said walls of said primary energy absorbing box has a castellated outer surface, comprising energy absorbing box bosses and energy absorbing box recesses that are staggered in sequence.
Preferably, said energy absorbing box bosses have a width of 40 mm, said energy absorbing box recesses have a width of 70 mm, and the height difference therebetween is 5 mm.
Preferably, said walls have a bending point at a central portion thereof.
Preferably, said walls has a bending angle of 4 degrees at said bending point.
In an embodiment, said primary energy absorbing box has a U opening at which said primary energy absorbing box is provided with at least one hinge.
In an embodiment, on the bottom of said secondary energy absorbing box are there boss structures with different heights.
In an embodiment, a backside opening structure is provided at the center of said boss structures.
Preferably, said backside opening structure is a 40 mm*15 mm square orifice.
In an embodiment, said energy absorbing device comprises a bumper system having a front bumper beam, said front bumper beam comprising a transverse beam that conforms to said bottom of said primary energy absorbing box.
Preferably, the gap between said transverse beam and said bottom is 8 mm.
The present invention further relates to a vehicle comprising said vehicle energy absorbing device as stated above.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of the holistic structure of a vehicle energy absorbing device according to the present invention;
FIG. 2 is a cross-sectional view of the holistic structure of the vehicle energy absorbing device according to the present invention;
FIG. 3 is a front structural view of the primary energy absorbing box of the vehicle energy absorbing device according to the present invention;
FIG. 4 is a rear structural view of the primary energy absorbing box of the vehicle energy absorbing device according to the present invention;
FIG. 5 is a longitudinal cross-sectional view of the primary energy absorbing box of the vehicle energy absorbing device according to the present invention taken along the line A-A of FIG. 3 ;
FIG. 6 is a front structural view of the secondary energy absorbing box of the vehicle energy absorbing device according to the present invention;
FIG. 7 is a longitudinal cross-sectional view of the secondary energy absorbing box of the vehicle energy absorbing device according to the present invention taken along the line B-B in FIG. 6 ; and
FIG. 8 is a perspective structural view of the front bumper beam of the vehicle energy absorbing device according to the present invention.
Wherein,
1 front bumper beam
11 transverse beam 12 securing structures at both ends
2 primary energy absorbing box
21 hinge 22 a bosses 22 b recesses 23 mounting structure 24 bottom of the U 25 wall of the U 26 U lower end snap structure 27 U upper end snap structure 28 bending point 29 opening of the U
3 skin 4 lower grid
41 energy absorbing box mounting structure of the lower grid
5 secondary energy absorbing box
51 backside opening structure 52 boss structure
6 upper grid
61 energy absorbing box mounting structure of the upper grid
7 peripheral vehicle parts
DETAILED DESCRIPTION OF EMBODIMENTS
Better embodiments of the present invention will be provided and described in detail with reference to the drawings.
The vehicle energy absorbing device according to the present invention comprises a bumper system, a primary energy absorbing box 2 and a secondary energy absorbing box 5 , wherein the bumper system has a front bumper beam 1 , a skin 3 , a lower grid 4 and an upper grid 6 , the positional relationship of which is shown in FIGS. 1 and 2 . The primary energy absorbing box 2 is fixed to the lower grid 4 and the upper grid 6 and arranged corresponding to the front bumper beam 1 , and the secondary energy absorbing box 5 is integrated onto the skin 3 and nested inside the primary energy absorbing box 2 . Since the front bumper beam 1 , the skin 3 , the lower grid 4 and the upper grid 6 are common structures of a bumper system, the mounting positions thereof will not be reiterated herein as they are not adjusted in the present invention. The specific structures added to those components or structures that are different from those in the prior art will be explained in detail.
With reference to FIGS. 3 to 5 , the specific structure of the primary energy absorbing box 2 of the vehicle energy absorbing device according to the present invention is shown as a thin-walled element extending transversely (in the width direction of the vehicle), the thin-walled element having a U-shaped cross-section in the longitudinal direction (in a driving direction of a vehicle), and an opening of the U 29 facing the front of the vehicle. The primary energy absorbing box 2 is shown in FIG. 2 as being installed between peripheral vehicle parts 7 and the front bumper beam 1 of the bumper system for absorption of the kinetic energy caused by crash, during the process of which the kinetic energy is transformed into deformation work to thereby prevent the front bumper beam from being permanently damaged in excess of critical load. To explain the dimension of the vehicle energy absorbing device of the present invention in a clearer manner, the dimension in the transverse direction is called a width, that in the longitudinal direction a depth and that in the vertical direction a height. In a preferred embodiment, the primary energy absorbing box 2 has a width of about 1000 mm and a depth of about 75 mm. The primary energy absorbing box 2 has a bottom 24 and walls 25 longitudinally extending therefrom. With reference to FIG. 2 , the walls 25 are provided at their ends respectively with an U lower end snap structure 26 and an U upper end snap structure 27 which are respectively snapped onto the lower grid 4 and the upper grid 6 . In the embodiment, the upper grid 6 has an energy absorbing box mounting structure 61 that cooperates with the U upper end snap structure 27 ; and the lower grid 4 has an energy absorbing box mounting structure 41 that cooperates with the U lower end snap structure 26 .
The primary energy absorbing box 2 is made of a plastic material, preferably being injection molded from a PP+EPDM+T10 (polypropylene, EPDM rubber, and 10% talc) modified material and having a wall thickness ranging from 2.5 mm to 3 mm. In a preferred embodiment, reinforcing rib structures are uniformly distributed within the primary energy absorbing box 2 at a location corresponding to the bottom 24 , and have a height of about 10 mm and a wall thickness of about 2.5 mm. The wall 25 has a castellated outer surface of a great-wall structure, comprising energy absorbing box bosses 22 a and energy absorbing box recesses 22 b that are staggered in sequence.
With reference to FIG. 3 , to increase the strength of the primary energy absorbing box 2 and prevent the primary energy absorbing box 2 from quick collapse in a crash, preferably, the energy absorbing box bosses 22 a have a width of 40 mm, and the energy absorbing box recesses 22 b have a width of 70 mm, and the height difference therebetween is 5 mm, so as to ensure that the walls 25 have a desired strength. In a preferred embodiment, the walls 25 have a bending point 28 at a central portion thereof to make the bottom gradually converge to facilitate deformation of the wall. Preferably, the bending angle is about 4 degrees. In a preferred embodiment, the opening 29 has a height of about 60 mm and the bottom 24 has a height of about 35 mm. At least one hinge 21 is arranged at the opening 29 so as to prevent the primary energy absorbing box 2 from losing too much stiffness due to the overlarge opening in the process of collapse; in addition, the hinge 21 can stabilize the shape of the primary energy absorbing box 2 before its installation, and meanwhile, the opening of the hinge structure makes it easier to install the hinge onto the bumper system. Preferably, the hinge 21 has a width of about 25 mm and there are three of them arranged. There is at least one energy absorbing box mounting structure 23 arranged at the opening 29 for snapping onto the bumper system.
The secondary energy absorbing box 5 of the vehicle energy absorbing device according to the present invention is integrated onto the skin 3 , and nested inside the primary energy absorbing box 2 . Please refer to FIGS. 6 and 7 for the specific structure of the secondary energy absorbing box 5 , which extends transversely as shown. On the bottom of the secondary energy absorbing box 5 are there boss structures 52 with different heights so as to guarantee a suitable strength of the secondary energy absorbing box 5 . A backside opening structure 51 is provided at the center of the boss structures 52 . The backside opening structure 51 not only reduces the weight of the skin 3 , but also lowers the strength of the secondary energy absorbing box 5 in a crash. In a preferred embodiment, the secondary energy absorbing box 5 has a depth of 30 mm and a height of 30 mm so as to ensure its contact with the bottom 24 if deformed. In a preferred embodiment, the backside opening structure 51 is a 40 mm *15 mm square orifice. In a preferred embodiment, the secondary energy absorbing box 5 is at the center of the primary energy absorbing box 2 , and the nesting amount of the secondary energy absorbing box is less than 10% of the depth of the primary energy absorbing box, that is, the distance between the secondary energy absorbing box 5 and the bottom of the primary energy absorbing box 2 is greater than 90% of the depth of the primary energy absorbing box 2 .
FIG. 8 shows the specific structure of the front bumper beam 1 of the vehicle energy absorbing device according to the present invention, which comprises a transverse beam 11 that extends transversely and securing structures 12 at both ends. The transverse beam 11 is an arc structure with its outer arc surface designed to conform to the bottom 24 . The securing structures 12 at both ends are secured to the bumper system by means of fasteners, such as screws. In a preferred embodiment, the overlap between the primary energy absorbing box 2 and the front bumper beam 1 is more than 80% because the primary energy absorbing box 2 if pleated due to collapse needs the front bumper beam 1 to provide a reverse support. The front bumper beam 1 is unable to provide an effective support if it slides with respect to the primary energy absorbing box 2 , hence, it is necessary to have them sufficiently overlapped. Preferably, the overlap between the bottom 24 and the transverse beam 11 is more than 80%. In a preferred embodiment, the gap between the bottom 24 and the transverse beam 11 is preferably 8 mm.
In the crash of a car with a pedestrian, the secondary energy absorbing box 5 of the vehicle energy absorbing device according to the present invention can provide continuous stiffness when the primary energy absorbing box 2 is nearly collapsed, so as to protect lower legs of pedestrians and reduce harms to legs of pedestrians. Specifically, when a pedestrian collides with the peripheral vehicle parts 7 in a crash, the primary energy absorbing box 2 collides with the transverse beam 11 of the front bumper beam 1 and collapses towards the opening 29 under the action of the transverse beam 11 to thereby absorb the collision energy. The bottom 24 collides with the secondary energy absorbing box 5 , such that the secondary energy absorbing box 5 collapses to thereby absorb the collision energy.
The above is only the preferred embodiments of the present invention and is not intended to limit the scope of the present invention. Variations can be also be made to the embodiments of the present invention, that is, any simple and equivalent variations and modifications made according to the claims and description of the present application fall into the protection scope defined in the claims of the present invention. Those that are not described in detail herein are customary technical content.
|
Example embodiments relate to a vehicle energy absorbing device that includes a primary energy absorbing box and a secondary energy absorbing box, the primary energy absorbing box having a U-shaped cross section with a bottom and a wall extending therefrom, the secondary energy absorbing box being nested inside the primary energy absorbing box. In the event of a collision between a car and a pedestrian, the secondary energy absorbing box of the vehicle energy absorbing device is configured to provide continuous stiffness when the primary energy absorbing box is almost collapsed, so as to protect lower legs of pedestrians and reduce harm thereto. The vehicle energy absorbing device can not only decrease harm to lower legs of pedestrians, but also reduce damage to automobiles as a result of a low-speed collision.
| 1
|
RELATED APPLICATION
[0001] This patent claims priority under 35 U.S.C. § 120 from International Application No. PCT/EP00/01 536, which was filed on Feb. 24, 2000.
FIELD OF THE INVENTION
[0002] The invention relates generally to firearms, and, more particularly, to a device for loading a cartridge into a cartridge chamber of a barrel of an automatic small arm.
BACKGROUND OF THE INVENTION
[0003] During cartridge loading, entrainment of a cartridge occurs via a bolt head on the front end of the bolt assembly of the weapon. A recess that forms a recessed percussion base can be situated on this front side of the bolt head. During reloading of the weapon, the uppermost cartridge of a magazine, the next cartridge of a horizontal belt feed, or the like, is brought into a feed position in front of the bolt head. A recoil spring pushes the bolt assembly and the bolt head forward. The cartridge is then moved forward together with the bolt assembly. During this forward movement, the cartridge is raised so that the rear end of the cartridge casing finally reaches the recess of the bolt head, if present. During subsequent forward movement, the cartridge is pushed into the cartridge chamber of the barrel. Because of the narrow tolerances between the engagement of the cartridge and the cartridge chamber, the cartridge is centered with respect to a center axis of the barrel or bore of the barrel. At the conclusion of the forward movement, the bolt assembly is connected to the barrel by means of a locking piece fastened on the barrel. This connection can be affected, for example, by rotation of the bolt head. The weapon is then in a loaded state.
[0004] The bolt assembly must then be centered with reference to the cartridge and the barrel. The centering of the cartridge relative to the bolt head is achieved by seating the rear end of the cartridge casing in the recessed percussion base of the bolt head. Substantial tolerances can be present between the bolt assembly and a housing that guides it to permit trouble-free functioning of the weapon even when heavily soiled. However, the tolerances between the engagement of the rear end of the casing and the percussion base of the bolt head must be close. The periphery of the percussion base must be countersunk, in order to facilitate entry of the cartridge into the percussion base.
[0005] A firearm, in which the barrel has a shoulder with a conical input opening behind the cartridge chamber, is described in U.S. Pat. No. 3,641,692. In that patent, the bolt assembly is introduced into the conical input opening during loading of the weapon. Substantial tolerances are present between the introduced bolt assembly and the shoulder. Centering of the bolt assembly with reference to the center axis of the barrel therefore occurs in the usual manner, namely, by the seat of the cartridge casing on the front end of the bolt assembly.
[0006] It is proposed in the small arm described in U.S. Pat. No. 3,225,657 to configure the outer surfaces of the front end of the bolt assembly to be conical. These outer surfaces come into contact with the also conically-shaped inside surfaces of a part coupled to the rear end of the barrel when the bolt assembly enters its forwardmost position to complete loading of the weapon. This engagement seals the barrel to the rear.
[0007] A cylindrical bolt assembly with extremely limited tolerances is known from U.S. Pat. No. 3,742,638.
[0008] U.S. Pat. No. 5,499,569 and U.S. Pat. No. 3,641,692 each includes an inner cone directly connected to the cartridge chamber to the rear which is engaged by an outer cone on the front side of the bolt assembly. In each case, however, the purpose of this cone is to prevent gas escape from the rear of the barrel. Centering is neither sought nor disclosed in these documents.
SUMMARY OF THE INVENTION
[0009] In accordance with an aspect of the invention, an apparatus is provided for use in a firearm. The apparatus includes a barrel having a center axis; a cartridge chamber; and a bolt assembly that can be displaced in the longitudinal direction of the weapon from a rearward position to a forward position to advance the cartridge into the cartridge chamber. The apparatus also includes a centering element rigidly connected to the barrel for centering the bolt assembly before the cartridge is completely introduced into the cartridge chamber as the bolt assembly moves from the rearward position toward the forward position. A center axis of the bolt assembly is not coaxial with the center axis of the barrel when the bolt assembly is in the rearward position. The center axis of the bolt assembly is coaxially aligned with the center axis of the barrel after centering by the centering element. The centering element comprises a cavity including recesses with outer surfaces which taper conically from a rear of the cavity to a front of the cavity.
[0010] In accordance with another aspect of the invention a firearm is provided which includes a barrel having a center axis; a cartridge chamber; and a bolt assembly mounted for movement from a rear position to a forward position to advance a cartridge into the cartridge chamber. The bolt assembly includes a center axis which is not in coaxial alignment with the center axis of the barrel when the bolt assembly is in the rear position. The bolt assembly further includes a bolt head defining a percussion recess. The percussion recess is dimensioned to receive a proximal end of the cartridge with clearance to permit transverse movement of the proximal end of the cartridge relative to the percussion base. The firearm also includes a locking piece adjacent the cartridge chamber for centering the bolt head as the bolt assembly moves from the rear position toward the forward position such that the center axis of the bolt assembly is substantially coaxially aligned with the center axis of the barrel. The center axis of the cartridge is not in coaxial alignment with the center axis of the barrel when the bolt head engages the cartridge. The center axis of the cartridge becomes substantially coaxially aligned with the center axis of the barrel after engagement of the bolt head and the cartridge but before the center axis of the bolt assembly becomes substantially coaxially aligned with the center axis of the barrel.
[0011] In accordance with another aspect of the invention, a method is provided for loading a cartridge into a cartridge chamber of a firearm. The method comprising the steps of: (A) advancing a bolt assembly in a longitudinal direction of the weapon; (B) engaging the cartridge with a bolt head of the bolt assembly at a first time when a center axis of the cartridge is not coaxially aligned with a center axis of the cartridge chamber and while a center axis of the bolt assembly is not coaxially aligned with the center axis of the cartridge chamber; (C) at a second time after the first time, centering the cartridge such that the center axis of the cartridge is in substantial coaxial alignment with the center axis of the cartridge chamber; and (D) at a third time after the second time, centering the bolt assembly such that the center axis of the bolt assembly is in substantial coaxial alignment with the center axis of the cartridge chamber.
[0012] Other features and advantages are inherent in the disclosed apparatus or will become apparent to those skilled in the art from the following detailed description and its accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a schematic illustration of a section of an exemplary small arm in a first position of an exemplary bolt assembly constructed in accordance with the teachings of the instant invention.
[0014] [0014]FIG. 2 is a view similar to FIG. 1 but showing the bolt assembly and cartridge in a second position.
[0015] [0015]FIG. 3 is a view similar to FIGS. 1 and 2 but showing the bolt assembly and cartridge in a third position.
[0016] [0016]FIG. 4 is a cross-sectional view of the bolt head of the automatic firearm depicted in FIGS. 1, 2 and 3 .
[0017] [0017]FIG. 5 is a cross-sectional view of the rear section of the locking piece of the firearm shown in FIGS. 1 - 3 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] A barrel 1 of an automatic firearm is shown in FIG. 1. The illustrated barrel is made of steel or titanium. A cartridge chamber 2 which is dimensional to receive a cartridge 3 (such as a belt cartridge) having a cartridge casing 4 is integral with the rear of the barrel 1 end section (on the right in FIG. 1). The inside diameter of a front cartridge chamber section 2 a (lying to the left in FIG. 1), is identical to the inside diameter of the barrel 1 . A central cartridge chamber section 2 b (lying to the right of the front cartridge chamber section 2 a in FIG. 1), has a larger inside diameter than the front cartridge chamber section 2 a . A rear cartridge chamber section 2 c (lying to the right of the center cartridge chamber section 2 b in FIG. 1), has a greater inside diameter than the center cartridge chamber section 2 b . The inside diameters of the barrel 1 and the front cartridge chamber section 2 a correspond to the outside diameter of a projectile on the front end of the cartridge 3 . The outside diameter of a front section 4 a of the cartridge casing 4 (lying to the left in FIG. 1), also corresponds to the inside diameter of the center cartridge chamber section 2 b . The outside diameter of a center cartridge casing section 4 b (lying to the right of the front cartridge casing section 4 a in FIG. 1), corresponds to the inside diameter of the rear cartridge chamber section 2 c.
[0019] A locking piece 5 is fastened to the cartridge chamber 2 . The locking piece 5 defines a continuous cavity 6 . An inside wall of a front section 5 a of the locking piece 5 (lying to the left in FIG. 1), lies on an outside wall 7 of the center and rear cartridge chamber sections 2 b , 2 c and is connected to those sections 2 b , 2 c.
[0020] A rear cartridge casing section (lying to the right in FIG. 1), has, on its rear end, a projection 4 d with greater outside diameter than the adjacent rear cartridge casing section 4 c . (As an alternative, the outside diameter of the rear cartridge casing section 4 c can also be equally large (not shown)). The rear cartridge casing section 4 c with projection 4 d is accommodated in a hollow cylindrical recess 8 a in a front end of a bolt head 8 b of a bolt assembly 8 (lying to the left in FIG. 1). The inside diameter of recess 8 a is greater than the diameter of projection 4 d of the rear cartridge casing section 4 c . A relatively large clearance is therefore present between an annular inside surface 8 c of recess 8 a and an annular outside surface of projection 4 d.
[0021] As shown in FIG. 4, the bolt assembly 8 has shoulders 8 d on the bolt head 8 b . These shoulders 8 d run in the longitudinal direction and extend outward from the bolt head 8 b at equal angular sections. Each of the shoulders 8 d has a flat outer surface 8 e and flat side surface 8 f that extend roughly in a horizontal direction (referred to FIG. 1).
[0022] Complementary to the shoulders 8 d of bolt assembly 8 , a rear section 5 b (lying to the right in FIG. 1 of the locking piece 5 ) has recesses 5 c as shown in FIG. 5. These recesses 5 c are arranged so that a guide rail 5 h is produced between every adjacent pair of recesses 5 c . The shoulders 8 d of the bolt head 8 then correspond in cross sectional shape to the recesses 5 c of the locking piece 5 . As shown in FIG. 1, the recesses 5 c and the guide rails 5 h run forward in the longitudinal direction from a front end of a rear part 5 f of the rear section 5 b of the locking piece 5 to a rear end of a front part 5 g of the rear section 5 b of the locking piece 5 . The front part 5 g of the rear section 5 b of locking piece 5 has the shape of a hollow cylinder.
[0023] As shown in FIG. 5, the recesses 5 c of the rear section 5 b of the locking piece 5 extend into the interior of the rear section 5 b of the locking piece 5 in the same angular sections as the shoulders 8 d . Each of the recesses 5 c has a flat inside surface 5 e and flat side surfaces 5 d . As shown in FIG. 1, the opposite inside surfaces 5 e of recesses 5 c taper conically forward and the opposite outside surfaces 5 i of guide rails 5 h run parallel. (In an alternative approach, the opposite outside surfaces 5 i of guide rails 5 h taper conically forward. The outer surfaces 5 i of guide rails 5 h then grade flatly into the inside surface of the rear part 5 f of the locking piece, and the guide rails 5 h are triangular in longitudinal section.)
[0024] The inside surface of the rear part 5 f of the rear section 5 b of the locking piece 5 has the shape of a cone that tapers from the rear to the front. The tapering is stronger than in the inside surfaces 5 e of recesses 5 c and, in the aforementioned alternative approach, stronger than in the outside surface 5 i of guide rails 5 h.
[0025] As shown in FIG. 5, the distance d′ between two opposite inside surfaces 5 e of recesses 5 c of the rear locking piece section 5 b becomes smaller from the rear to the front. (The same applies in the aforementioned alternative approach for the distance between two opposite outside surfaces 5 i of guide rails 5 h .) The distance d′ between two opposite inside surfaces 5 e of recesses 5 c is minimal on a front end of the recesses 5 c and, at that front end, corresponds to the distance d″, (see FIG. 4), between two opposite outside surfaces 8 e of the bolt head 8 and to the inside diameter of an inside wall of the adjacent hollow cylindrical front part 5 g of the rear section 5 b of the locking piece 5 . (Similarly, in the aforementioned alternative approach, the distance between two opposite outside surfaces 5 i of the guide rails 5 h is minimal on a front end of the guide rails 5 h , and, at that front end, correspond to the distance between two opposite inside surface 8 i between two shoulders 8 d of the bolt head 8 .)
[0026] When the firearm is being loaded, the bolt assembly 8 is initially moved forward in the direction of the position depicted in FIG. 1 by the recoil spring (not shown). The bolt assembly 8 then pushes the cartridge 3 forward. The cartridge 3 is lifted as it is moved forward. In the illustrated device, the rear cartridge casing section 4 c of cartridge 3 is introduced into the recess 8 a of the bolt head 8 b when the cartridge is lifted. On further forward movement of the cartridge 3 , an outer wall of the projectile comes into contact with an inside wall of the rear cartridge chamber section 2 c , and then an inside wall of the middle cartridge chamber section 2 b (see FIG. 1).
[0027] A center axis n of the bolt assembly 8 or recess 8 a of the bolt head 8 b lies skewed or parallel to (but offset from) a center axis m of the barrel 1 . The bolt assembly center axis n is, therefore, still not centered with reference to the barrel center axis m. The same applies for a center axis of the cartridge (not shown), namely, it is not centered with respect to the barrel center axis m.
[0028] If the bolt assembly 8 and the cartridge 3 are moved farther forward in the direction of the position depicted in FIG. 2, the outer wall of the projectile of cartridge 3 comes in contact with an inside wall of the front cartridge chamber section 2 a . Since, as explained, the inside diameter of barrel 1 and the front cartridge chamber section 2 a are equal to the outside diameter of the projectile of the cartridge 3 , the center axis (not shown) of the cartridge 3 becomes centered on the barrel center axis m by virtue of this movement. On the other hand, the center axis n of bolt assembly 8 is initially still not centered with the barrel center axis m. To enable this centering of the cartridge 3 while the bolt head 8 b remains off-center, a clearance is present between the annular inside surface 8 c of the recess 8 a and the outside surface of the projection 4 d of cartridge 3 , as explained above.
[0029] On further forward movement of the bolt assembly 8 , the front cartridge casing section 4 a reaches the center cartridge chamber section 2 b . A front edge between the outer surface 8 e of the shoulder 8 d (lying on the bottom in FIG. 2) of the bolt assembly 8 and its front surface 8 g initially touch the inside surface of the rear part 5 f and then the inside surface 5 e of the recess 5 c (also lying on the bottom in FIG. 2) of the rear section 5 b of the locking piece 5 . Because of the conical tapering of the inside surface of the rear part 5 f and the inside surface 5 e of recess 5 c , the bolt assembly 8 is raised during its further forward movement until finally, in the position depicted in FIG. 2, the center axis n of the bolt assembly 8 is centered on the barrel center axis m. The edge of the bolt assembly 8 has then reached the front part 5 g of the rear locking piece section 5 b . As mentioned above, at this position the distance d′ between two opposite outside surfaces 5 e of the recesses 5 c of locking piece 5 corresponds to the distance d″ between the two opposite outside surfaces 8 e of the shoulders 8 d of bolt head 8 .
[0030] If the bolt assembly 8 and the cartridge 3 are moved farther forward in the direction of the position shown in FIG. 3, the outer surfaces 8 e of the shoulders 8 d of the bolt assembly 8 touch the inside surface of the adjacent hollow cylindrical front part 5 g of the rear section 5 b of the locking piece 5 . The bolt assembly 8 is then guided farther forward in the hollow cylindrical front part 5 g along the bolt assembly center axis n with relatively limited clearance.
[0031] Finally, as shown in FIG. 3, the cartridge casing 4 reaches the cartridge chamber 2 and the front surface 8 g of the bolt assembly 8 lies immediately in front of a rear side surface 2 d of the rear cartridge chamber section 2 c . The shoulders 8 d of the bolt head 8 b now lie in front of the guide rails 5 h of the locking piece 5 . In this position, the bolt head 8 b can be rotated in the usual manner and, on this account, the bolt head 8 b can be fixed with the locking piece 5 and, thus, with the barrel 1 against displacement in the longitudinal direction by positioning the shoulder 8 d in front of the rails 5 h.
[0032] A cavity is formed by the bolt assembly 8 in the longitudinal direction that accommodates a firing pin 9 . A rear outer surface 4 e of the cartridge casing 4 (lying to the right in FIG. 3), lies against a side surface 8 h of the recess 8 a of the bolt head 8 b . When cartridge discharge is desired, the firing pin 9 is moved forward so that its front end emerges from the side surface 8 h of the recess 8 a of the bolt head 8 b to strike and, thus, fire cartridge 3 .
[0033] As used herein, “centering of the bolt assembly” is understood to mean generally aligning a center axis n of the bolt assembly 8 with the center axis m of the barrel 1 or, preferably, the center axis of the cartridge chamber. Before alignment, the center axis of the bolt assembly 8 is skewed or parallel to (but offset from) the center axis m of the barrel. After alignment, these axes m,n lie roughly, but preferably precisely, coaxially to each other. In the narrower sense, “centering of the bolt assembly” is understood to mean centering of the center axis n of the bolt head 8 of the bolt assembly (or preferably a center axis of the percussion base or, if present, the recess in the bolt head 8 that serves to accommodate the cartridge casing 4 ) with the center axis of the cartridge chamber.
[0034] In the disclosed device, this centering is achieved by a centering element connected to the barrel and not (or only partially) via the seat of the rear end of the casing 4 in the recess in the bolt head 8 b . Therefore, relatively large tolerances preferably exist between the periphery of the cartridge casing 4 and the percussion base formed in the bolt head 8 b . During centering of the cartridge 3 during its insertion into the cartridge chamber 2 , the bolt assembly 8 is not centered by the cartridges (or is only partially co-centered). Because of this, the cartridge 3 is less severely loaded during the loading process. This is a particular advantage in cartridges with sensitive rounds.
[0035] The bolt assembly 8 is also aligned with greater accuracy to the bore of the barrel 1 by the centering process disclosed herein. On this account, after each loading, compatibility conditions are ensured during firing. The disclosed device is, therefore, particularly advantageous in sharpshooter weapons.
[0036] The bolt assembly 8 or bolt head 8 b is centered by the centering element during a forward displacement of the bolt assembly 8 . As used herein, “forward displacement” is understood to mean displacement of the bolt assembly 8 in the direction of the cartridge chamber 2 and away from the shooter. When the bolt assembly 8 is being centered, the cartridge 3 is already centered with reference to the barrel 1 . As an alternative, the cartridge can be centered by the bolt assembly 8 , preferably immediately before or shortly before the cartridge reaches the cartridge chamber. The cartridge is advantageously already in the cartridge chamber during centering of the bolt assembly.
[0037] The centering element is directly connected to the barrel 1 . The connection between the barrel 1 and centering element is preferably not releasable. By integrated design of the centering element, even greater accuracy during centering of the bolt assembly 8 with reference to the barrel 1 is achieved. Addition of component tolerances is avoided. Because of this, further improved accuracy is achieved. As an alternative, the centering element and the barrel, and/or the centering element and the cartridge chamber can be integrally formed. The accuracy of centering is therefore even further increased.
[0038] The centering element advantageously centers the bolt assembly 8 via its bolt head 8 b . As explained above, the bolt head 8 b on the front end of the bolt assembly 8 entrains the cartridge casing. If centering of the bolt assembly 8 occurs via the bolt head 8 b , the bolt head is centered relatively accurately, and, therefore, so is the percussion base recessed in the bolt head 8 b . Because of this, particularly uniform compatibility conditions during firing are achieved and firing accuracy is increased. Moreover, the functional reliability of the bolt assembly system is improved in the disclosed device.
[0039] The centering element is preferably arranged next to the cartridge chamber 2 , and the bolt assembly 8 is centered next to the cartridge chamber 2 .
[0040] The cartridge 3 is centered during centering of the bolt assembly 8 by the centering element. Greater accuracy during introduction of the cartridge 3 into the cartridge chamber 2 is achieved on this account. The inside wall of the cartridge chamber 2 and the outside wall of the cartridge 3 , especially the round, are therefore less heavily loaded during loading. Moreover, greater independence is achieved in cartridge geometry. The cartridge 3 need not (or need only partially) center itself by a correspondingly designed outer wall. Preferably, the cartridge 3 is initially roughly pre-centered by the bolt assembly 8 , for example, immediately before or shortly after its introduction into the cartridge chamber 2 by engagement of the bolt assembly 8 on the cartridge casing. Fine centering of the cartridge 3 then occurs in the usual manner on contact of the outer wall of the cartridge 3 and inner wall of the cartridge chamber 2 .
[0041] The bolt assembly 8 is centered by a surface of the centering element lying obliquely with respect to the longitudinal direction of the weapon. The surface is preferably sloped in the direction toward the barrel I or cartridge chamber 2 . If a front edge of the bolt assembly 8 strikes this surface during forward displacement in the longitudinal direction of the weapon, the bolt assembly 8 is displaced in the transverse direction. Because of this transverse displacement, the center axis of the bolt assembly 8 can be advanced on the bore of the barrel 1 . As an alternative, a similar effect can be achieved by a surface of the bolt assembly 8 lying obliquely to the longitudinal direction of the weapon that is sloped in a direction toward the barrel.
[0042] Centering of the bolt assembly 8 can occur by the obliquely lying surface of the centering element and by an additional obliquely lying surface of an additional centering element. The two surfaces advantageously lie opposite each other. The additional centering element is preferably directly connected to the barrel and designed integrally. With particular advantage, however, the obliquely lying surface and a second obliquely lying surface, through which the bolt assembly 8 is centered, are provided on the same integral centering element. Because of this, addition of tolerances between different components is prevented. Further increased accuracy during centering of the bolt assembly 8 is therefore achieved.
[0043] The centering element has a continuous cavity 6 . Centering of the bolt assembly 8 is then advantageously achieved by the fact that a conical inside surface of a first section of the cavity 6 tapers from the rear to the front. As an alternative, an outer surface of the bolt assembly 8 can also taper conically from the rear to the front.
[0044] The cavity 6 advantageously has recesses 5 c , whose inside surfaces 5 e taper conically from the rear to the front. If the bolt assembly 8 has shoulders 8 d which are complementary to the recesses 5 c of the cavity 6 , in addition to centering of the bolt assembly 8 , rotation of the bolt assembly 8 is simultaneously prevented. The outer surface(s) of the bolt assembly 8 , especially the outer surfaces of the shoulders 8 d , then extend in the horizontal direction. A device in which the outer surfaces of the guide rails formed between two adjacent recesses 5 c of the cavity 6 taper conically from the rear to the front, is preferred.
[0045] After centering of the bolt assembly 8 , the bolt assembly is advantageously guided into the centered position with reference to the barrel 1 . For this purpose, the centering element preferably has a hollow cylindrical section 5 g . The inside diameter of the hollow cylindrical section 5 g is advantageously roughly equal to an outside diameter of the bolt head 8 b . Because of this, sealing of the cartridge chamber 2 outward is achieved. Soiling of the weapon housing on release of gases during firing is thus reduced. As an alternative, it is conceivable to guide the bolt assembly 8 between at least two guide elements in front of the cartridge chamber 2 in the centered position.
[0046] As an alternative, the bolt assembly can have grooves, whose inside surfaces taper conically from the rear to the front. Outer surfaces of rails formed between two grooves of the bolt assembly then also taper conically from the rear to the front. The inside surfaces of the complementary recess of the cavity then preferably extend in the usual manner in the horizontal direction. The outer surfaces of guide rails formed between the two recesses are then also parallel.
[0047] The centering element is preferably part of a locking piece and, with particular preference, integrated with it. The locking piece serves to lock the bolt assembly 8 with the barrel 1 after the bolt head 8 b is introduced into the cartridge chamber 2 . Since the locking piece is fastened to the barrel 1 , with integral design of the centering element locking piece, a separate fastening for securing the centering element on the barrel 1 can be dispensed with.
[0048] Although certain apparatus constructed in accordance with the teachings of the invention have been described herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all embodiments of the teachings of the invention fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents.
|
An apparatus for loading a cartridge into a cartridge chamber of a firearm is provided. The apparatus includes a barrel, and a bolt assembly mounted for movement from a rear position to a forward position to advance a cartridge into the cartridge chamber. The bolt assembly includes a center axis which is not in coaxial alignment with the center axis of the barrel when the bolt assembly is in the rear position. The bolt assembly further includes a bolt head defining a percussion recess. The percussion recess is dimensioned to receive a proximal end of the cartridge with clearance to permit transverse movement of the proximal end of the cartridge relative to the percussion base. The firearm also includes a locking piece adjacent the cartridge chamber for centering the bolt head as the bolt assembly moves from the rear position toward the forward position such that the center axis of the bolt assembly is substantially coaxially aligned with the center axis of the barrel. The center axis of the cartridge becomes substantially coaxially aligned with the center axis of the barrel after engagement of the bolt head and the cartridge but before the center axis of the bolt assembly becomes substantially coaxially aligned with the center axis of the barrel.
| 5
|
RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 60/390,863, entitled “Interactive Document Capture and Processing Software,” filed Jun. 21, 2002.
FIELD OF INVENTION
[0002] The present invention relates to software for organizing and processing the scanning and/or copying of a large volume of documents.
BACKGROUND OF THE INVENTION
[0003] For many years, businesses such as commercial copy shops have copied large volumes of documents. In a typical scenario in the photocopy industry, the life of a copy project starts by the client calling the copy vendor to have an order picked up. Job instructions are written down at the client's office on a preprinted order form. The client then requests that copy shop make one (or multiple) set of copies of the documents in the identical format (i.e., with identical separators) and order as the original. For example, pages stapled together in the original should be stapled together in the copies.
[0004] Once the project is brought into the production facility, the copy center manager will assign a number to the order and, depending on the size of the order, he will break the order up into manageable copy sections. He will then identify every section by writing a label known as the Production Tracking Sheet using the job name, job #, box #, and section number. The machine operator will receive the section to copy and a Production Tracking Sheet to log productivity and billing numbers. The copy shop operator then assigns its employee(s) the task of copying the documents in the boxes. The employees remove each physical page break (e.g., staple, clip, etc.), use standard copy machines to make copies of the documents and then assemble the copied documents in the same format and order as the originals.
[0005] Photocopy centers generally perform a quality control check on copies produced. Usually, a separate employee will manually compare the copied and original documents to minimize errors. They will page check each copy against the original by flipping one page at a time and viewing both the fronts and backs. If a user needs to go directly to a folder towards the middle or end of a box, they can simply grab the file from the stack of originals and then grab the corresponding file from the stack of copies.
[0006] Thereafter, labels with sequential numbers are applied to the copied pages. During the manual page numbering process, the photocopy facilities print a numeric sequence of numbers on rolls of small label stickers, 1 ½″×¾″, then a production employee applies the label stickers using a machine which automatically advances the rows of labels as they are pulled from the sheet. Labels are applied, one at a time, to the documents, normally in the header or footer region. This process obviously is very labor intensive. One standard box of 3,000 documents can take roughly two hours to label. Additional copy sets are optionally made using the numbered copied documents.
[0007] After the project is copied and verified for quality control it is reassembled and then invoiced. Finally, the original and copied boxes are reassembled and delivered to the client. Most of the tasks during the project lifecycle are either fractionally automated or handled manually, and thus the current state of technology requires a labor intensive approach for these services.
[0008] Accounting procedures for order management, billing, collections, time clock management and order processing are all manual or fragmented automated procedures. Job orders are entered manually into a book of orders, written on a job board, sectioned off manually, processed and then the meter readings are tallied up. Some facilities use generic spreadsheets or equivalent software to calculate invoices.
[0009] Traditional scanning software requires bar coded sheets to log type and placement of page breaks. This means that the user must place a particular bar coded sheet before each document break (i.e., paper clip). This approach has difficulty capturing multiple levels of document breaks. Bar coded sheets that identify the beginning of a document require document “preparation” and is a labor intensive task. Bar code users pay to first produce the sheets and then they pay the software provider when the sheets are scanned. A need exists for an efficient method for managing the document capture workflow using a single computer application. It would be cost effective to manage the job information, division of jobs between employees, and other functions in a single computer application.
[0010] A need exists for an easy and accurate system and method for obtaining important information about documents in a computer memory. Information including the document image and the order and location of the various document separators would be very helpful in efficiently making copies of documents. It is not unusual for a client to request multiple copy sets at different times. Without such information stored in a convenient format in a computer, the entire copying process needs to be repeated each time (including removing all the physical page breaks).
[0011] Finally, a need also exists for a method to view an electronic version of multiple documents using a computer interface. This will reduce manual hours needed and increase efficiency in both quality control and arranging for multiple sets of copies of the same job.
SUMMARY OF THE INVENTION
[0012] The present invention comprises an efficient method for managing the document capture workflow using a single computer application.
[0013] The present invention is primarily designed for photocopy centers which are comprised of vendors that operate 24 hours per day, seven days per week, although the features of the present invention may be utilized by anyone. Photocopy centers may include in-house copy centers, off-site copy centers and retail copy services.
[0014] The present invention is intended to automate and integrate the stages of the photocopy production process. The invention provides an efficient means of entering customer orders into the system, capture document images, print additional sets on demand, reconstruct all physical page breaks in the additional copy sets without having the originals or a hard copy to guide the machine operators through the process, create billing summaries and provide a signed invoice search and retrieval application. The application will also provide detailed and accurate reporting for production productivity, customer usage and employee time cards.
[0015] In one aspect, the present invention includes a system for obtaining information about documents in a computer memory using a touch-screen monitor. The touch-screen monitor includes easy to use buttons that can capture document images, various information about physical page break separators and other important document information.
[0016] Finally, in a further aspect, the present invention enables a user to view an electronic version of multiple documents using a computer interface in the form of a document image tree. The document tree includes the important information about multiple pages and documents, as well as contains an image of the pages.
[0017] For purposes of the present invention, the phrase “physical page break” (PPB) shall mean anything that connects or otherwise affiliates multiple pages that belong or are intended to be together in the original documents. PPB includes items such as a paperclip, rubber band, binder clip, file folder, book binding, file pocket, index tab, staple and other logical document breaks known to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIGS. 1 - 8 show flow diagrams for the present invention.
[0019] FIGS. 9 - 16 show touch-screen displays for a preferred embodiment of the present invention.
[0020] [0020]FIG. 17 shows a touch-screen display for an alternative embodiment of the present invention.
DETAILED DESCRIPTION
[0021] The present invention consists of interactive document capture and processing software (IDCP) 1000 , and is comprised of three software application components. The software is directed to any user and may be particularly useful and desirable for photocopy users and implementation into any xerographic duplicating center. The three components are a document capture component 10 , a quality control component 1004 , and a workflow management component 1006 . It is understood that the software may be implemented in hardware or any computer readable medium.
[0022] FIGS. 1 - 8 show the general logic of computer capturing and processing software. I-CAP is flexible enough to accommodate the PPB cues through three mediums; touch-screen monitor, voice recognition, or by inserting page break sheets. Turning first to FIG. 1, a user logs into the system at node 12 . This may include an employee number, name or other identifying information. Next, at node 14 , the user loads the job process, as described in more detail below and illustrated in FIG. 2.
[0023] The capture process is next. The user starts at a particular page in the original documents, and continues forward page by page. At each page, the user decides at node 18 if any PPB's are present. If a PPB is present, the user proceeds to page break process node 16 which is described in more detail below and illustrated in FIG. 3. If no PPB is present after node 16 has been performed, the user performs scan process 20 . Scan process 20 is also described in further detail below and illustrated in FIG. 2. The user then checks if the PPB pages are finished at node 24 . By this, applicant is referring to a set of pages within a particular PPB. If a PPB was present and the pages associated with that PPB have all been scanned, the PPB is physically replaced on the original document at node 22 and the user selects the PPB end button at node 25 . Thereafter, the user continues copying more documents at node 26 and repeats the process. When the user is done, at node 30 the user enters whether the entire job is complete. The job may either be parked if the job is not done (at node 32 ) or ended at node 28 . The user thereafter may work on a totally separate job at node 34 in which the entire job process is repeated. Finally, the user logs out at node 36 and ends work at node 38 .
[0024] Turning now to FIG. 2, the load job process node 14 and scan process node 20 are illustrated with additional detail. When loading a new job, at node 40 , a user is able to select from the various jobs and work assigned to him or her. The user selects which job to work on at node 40 and confirms it at node 42 , ending the load job process at node 44 . Scan process node 20 is how the pages are scanned into computer memory. It is understood that electronic images or copies of the documents may be obtained by other methods as well, such as uploading through the internet, electronic files on a CD, etc. First, a document is placed on the scanner at node 46 . The scanner start button is pressed at 48 and pages are scanned at node 50 . Pages are then removed from the scanner at node 52 and the user continues scanning pages at 54 until end 56 . In scan process 20 , multiple pages are scanned, provided there are no PPB's between the pages.
[0025] [0025]FIG. 14 illustrates another screen capture 260 from the present invention. Screen 260 permits the manager to view important information about a job. For example, all presently active jobs are displayed by number and client name at area 262 . Tab bar 274 summarizes all of the functions the manager can perform. When a user selects a particular job at area 262 , the associated job information is displayed at area 264 . Information on the boxes is displayed and may be edited at area 266 . Boxes may be added, deleted or CDs may be imported at area 268 . The progress on the job is summarized in area 270 with the ability to modify that at area 272 .
[0026] [0026]FIG. 17 illustrates screen capture 284 which is an alternative embodiment of the present invention. Job information 286 is displayed with further detail. Box and job status information 288 is also provided in an easy to read format on a single screen.
[0027] [0027]FIG. 3 illustrates page breaks node 16 . First, the user removes the physical page break (i.e., the staple) from the original document at node 58 . At node 60 , the user selects which type of physical page break was removed. This is preferably done through a touch-screen computer monitor; however, it is understood that this can be accomplished by voice recognition or even use of a computer keyboard. The main physical page breaks are redweld 62 , binding 64 , binder clip 66 , staple 68 , other 70 , logical break 71 , folder 72 , rubber band 74 , paper clip 76 and index tab 78 . If a user selects either redweld 62 or folder 72 , folder size selection node 80 is utilized. This is illustrated in FIG. 4 and described below. Index tab 78 utilizes index tab selection 84 which is also illustrated in FIG. 4. Binder 64 and other 70 utilizes book binding selection 82 and other selection 86 , respectively, which are illustrated in FIG. 5 and also described below. The page break data is then saved at node 88 . The system remembers which PPB's are open by adding a corresponding end page break button in the open document stack at node 90 . At node 92 , the user enters whether there are multiple levels of PPB's. By this, applicant refers to a document which contains more than one PPB's. For example, six pages may be paper clipped together, the first three of the six pages stapled to themselves and the second three of six pages stapled to themselves. The present invention is able to accurately keep track of all PPB's information, even intertwined PPB's. Finally, page breaks node 16 ends at node 94 .
[0028] [0028]FIG. 4 illustrates both index tabs selection 84 and folder size selection 80 . Index tabs selection 84 allows the user to select the type of index tab at node 96 . This includes various types including for example a number 98 , alphabetical character 100 or customized text 102 . The tab information is entered, preferably on the touch-screen monitor at node 104 and the relevant information is stored and saved in computer memory (or otherwise) at node 106 . Finally, index tabs selection 84 ends at node 108 .
[0029] Folder size selection 80 permits the user to select the folder size, usually either eleven inches or fourteen inches at node 110 . This information is saved at node 112 . The user optionally may input text (numbers, alphabetical characters, or entirely customized text) which is searchable at nodes 114 and 116 . This information is saved at node 118 , the PPB information saved at node 120 and the selection ends at end 122 .
[0030] [0030]FIG. 5 illustrates book binding selection 82 and other selection 86 . Book binding selection 82 permits the user to select the type of binding at node 124 . The type of binding includes, for example, spiral bound 126 , velo-bound 128 , two hole drill binding 130 and three hole drill binding 132 . The spiral bound and velo-bound type may be done at either the top or the side at node 134 . The PPB and related data are stored at 136 and this selection ends at 138 . Finally, other selection 86 includes entering data (customized) at node 140 , saving PPB and relevant information at 142 and ending at 144 .
[0031] [0031]FIG. 6 illustrates the method for processing jobs after capture, known as orders out 300 . A user selects a job, preferably from the rail on the left side of the screen at node 302 . The user selects from the various preprocess 304 options such as performing optical character recognition on the documents (nodes 306 and 308 ) and numbering the pages on the documents (nodes 310 , 312 and 314 ). Numbering the pages, otherwise known as endorsing, is described in more detail below and illustrated in FIG. 7. Once the preprocessing items, if any, have been selected, the processing is started at nodes 316 and 318 . Loadfiles may be created and edited if desired at nodes 320 , 322 , 324 , 326 and 328 . The edit loadfiles process is described below and shown in FIG. 7. The user may optionally burn the data on a CD at nodes 330 and 332 (see also FIG. 7) or export the data to a network or anywhere else at nodes 334 and 336 (see also FIG. 8). For space or other reasons, the data, especially the images, may be deleted from the server at nodes 338 and 340 (see also FIG. 8). Finally, the billing for the processed job may be reviewed at node 342 and billable copies may be selected at node 344 . When a user is finished processing at node 346 , orders out 300 ends at node 348 .
[0032] [0032]FIG. 7 illustrates the endorse options process 350 , edit loadfiles process 370 and burn CD process 382 . For the endorse options process 350 , a user may select a prefix that should appear on the documents before the numbering at nodes 352 and 354 . Typically, these are several letters which identify the source of the documents. The user can select the first number at which to start numbering at nodes 356 and 358 . Optionally, a user can select a suffix (nodes 360 and 362 ) and/or a second line of text (nodes 364 and 366 ) to be endorsed on the documents. For the edit loadfiles process 370 , the user selects which loadfile to edit (nodes 372 and 374 ), edits the loadfiles and then exits. For the burn CD process 382 , the user selects the burn option 384 , selects which data to burn at node 386 , selects the loadfiles at node 388 , inserts a CD at node 390 and starts the process.
[0033] [0033]FIG. 8 illustrates the export process 398 and delete images process 412 . Export process 398 involves selecting the export option (node 400 ), selecting which data to burn (node 402 ), selecting the loadfiles (node 404 ), specifying a target directory (node 406 ) which can be on the same computer, another networked computer or any other directory or storage device. Delete images process 412 permits deletions of images (node 422 ). To prevent inadvertent deletions, the preferred embodiment requires two separate confirmations (nodes 414 , 416 , 418 and 420 ) before deletions.
[0034] One aspect of the present invention is called I-CAP 102 , an interactive document scanning software application that features a touch-screen monitor and open document stacking (OD Stack) technology. OD Stack technology means that the software, by means of a data structure for storing items which are to be accessed in last-in first-out order, keeps track of PPBs. The software also keeps track of each PPB's parent, siblings and children. For example, take a job including a folder containing (i) eight pages stapled together; (ii) three pages paper clipped together; and (iii) a subfolder with 5 pages stapled within it. First, folder is pushed to the OS Stack. Then, staple is push onto the OS Stack, now containing both folder and staple. Then, the staple is popped from the OS Stack, leaving the folder alone on the OS Stack. Then the paper clip is pushed onto the stack, now containing both folder and paper clip. Then the paper clip is popped from the OS Stack, leaving the folder alone again. Thereafter, the subfolder is pushed onto the OS Stack (containing now folder and subfolder), and then the staple is pushed onto the OS Stack (containing now the folder, subfolder and staple). Finally, the staple, then subfolder, then folder and popped from the OS Stack, leaving the stack empty. The software maintains a record of each PPB, who the PPBs' parents and children are (from the OS Stack), who the PPBs' siblings are (historic from OS Stack) and how the pages are organized.
[0035] As illustrated in FIGS. 9 and 10, the interactive software displays a menu of buttons on a touch-screen monitor at the copying or scanning station. Job information such as job number, company name, box number, etc. are displayed in area 172 . Start button 186 initiates the scanning of a page of a document. Single sided button 158 and double sided button 160 are used to provide information as to the original document to be scanned to communicate with the scanner. The present invention maintains and affiliates the single/double sided information with the scanned pages for use in creating the copy. Scanner setting button 192 allows a user to make changes to the scanner such as brightness, contrast and backside drop. The size of the page to be scanned can be set as 8 ½″×11″ (button 152 ), 8 ½″×14″ (button 154 ) or 11″×17″ (button 156 ). Alternatively, the scanner can be set to landscape or portrait. The image may be rotated (landscape/portrait) by 180 degrees (or any other number of degrees) at button 162 , which typically used if the originals are of poor quality on one portion of the page.
[0036] During the scanning copying process, physical page breaks (PPB) are removed from the paper in order to place those documents in the machines. When a PPB is removed, the user will touch the corresponding PPB button from the menu of buttons to identify the beginning of a document. For example, a user may touch staple button 166 , paper clip button 168 , binder clip button 170 , rubber band button 174 , folder button 176 , binding button 178 , tabs button 180 , redweld button 184 , the logical break button 188 or the miscellaneous/other PPB button 182 . An icon of the PPB is also displayed within the button for ease of use. Every PPB is considered a document level and each open level is displayed on rail 198 as a stack of “End Document” buttons down the left side of the application screen (OD Stack). Once the last page of a document is scanned, the user will touch the corresponding end button from the OD Stack to identify the end of the document. There is no limit to the number of page breaks opened at one time. For example: a file folder with four levels of subdocuments would be logged, for example, by touching the file folder button 176 , then the rubber band button 174 , the binder clip button 170 , the paper clip button 168 and then the staple button 166 . At the end of the stapled document, the user will touch the end staple button 200 . If there is another stapled group, the user will touch the staple button 166 from the menu of PPB's to identify a new staple group. The user can also hit the park/end button 196 to cease work on a job at any time. The preferred embodiment of the present invention includes start/staple button 164 which performs the functions of all of staple button 166 , start button 186 and end staple button in a single button. It is understood that, similar to the start/staple button 164 , any PPB can be combined with the scan button into a single button. All other PPB's will remain open until the user finishes scanning the last page of each PPB level. Open PPB's (the OS Stack) are displayed on rail 198 , which is illustrated as vertical on the left side of the computer monitor. For example, in FIG. 10, the document being scanned currently has an open rubber band 202 , manila folder 204 and redweld 206 . Undo button 190 can be used to undo the last button touched by the operator. It should be understood that instead of a touch-screen monitor, voice recognition software or devices, keyboard, mice, foot pedals, headsets or other devices may be used to register the PPB's.
[0037] This process of capturing PPB's will create a hierarchy of document levels and can be viewed using the history button 194 or in the QC application. The hierarchy of documents built during the scanning and/or copying process is referred to as the Document Image Tree (DIT) and is displayed as illustrated in FIG. 11. If a box contains three expandable file folders, the application will show an expandable folder icon for each one. When a user wants to view the contents of the folder they can touch the folder icon and the sublevels of documents will be displayed. By touching any particular page, the image of the page appears on the monitor. The history of a document is updated simultaneously with the input of the page image and the PPB information.
[0038] [0038]FIG. 11 illustrates a screen capture from the electronic-document tree in the history view 208 . The different PPBs are displayed with icons, and the number of pages within each PPB are listed. The “+” symbol 212 indicates that all sub PPBs and pages are closed (and thus not displayed) within the tree. This is useful to permit more information to be visible on a single screen. The “−” symbol 210 indicates that the PPB is open and sub PPBs/pages are displayed. When touching or otherwise indicating a specific page on the electronic document tree, image 218 of the associated page is displayed. It should be understood that image 218 may be displayed as the complete image of the document, a zoomed partial image or a cutoff image. Button 214 permits an image to be rotated, if for example, it was copied in the wrong orientation. Button 216 permits conversion from duplex to simplex. Button 215 deletes a page or PPB and button 213 permits insertion of additional pages or PPBs.
[0039] I-CAP's primary function is to identify and store the location of each and every PPB, by the touch of a button, while converting paper documents into digital images. This approach is facilitated by use of a touch-screen monitor. In the preferred embodiment, I-CAP is comprised of finger-sized electronic buttons which display icons of corresponding page breaks. When a machine operator removes a paperclip from a document, they touch the button with the paperclip icon. The application will then display an open paperclip button in the Open Document Stack (OD Stack).
[0040] OD Stack Technology was created to give machine operators a view of open PPB levels and to provide a simplified method to identify the end of a document. Bar coded sheets are not practical for identifying the end of documents. There are two methods for bar coded sheets to mark the end of documents; by inserting additional bar coded sheets or by assuming the next begin document bar coded sheet is the end of the previous document. End users of the images will not have to have any detail on the origins or levels of documents unless they incur additional document preparation charges. With the OD Stack Technology, users can view every open level of document and by touching a button they can simply and easily end a document by the touch of a button. The OD Stack Technology does not require additional labor, additional fees to either vendors or end users, and does not limit the number of document levels that can be captured.
[0041] The combination of a touch-screen monitor and OD Stack technology provide easy to use and operate software. In the preferred embodiment, this application does not use a keyboard or a mouse for any function or task, although it is understood that such device may be utilized if desired. The user interface displays buttons with icons of commonly used PPB's.
[0042] Another aspect of the present invention is called I-QC 1004 , a supporting application to the I-CAP software. The process is based on surfing through the hierarchy of images with a touch-screen monitor or voice recognition commands. The user will check every image against the originals for industry quality standards. The DIT is used to go directly to any particular document or page, move documents in the hierarchy, delete documents, or insert new documents all by the touch of an electronic button on the monitor. The application will let the user surf from page to page or from document to document while viewing the desired image at the same time.
[0043] [0043]FIGS. 12 and 13 illustrate a screen capture from the electronic document tree in the QC view 220 . FIG. 12 is the document-level screen capture and FIG. 13 is the page-level screen capture. Electronic tree 240 is similar to that described above in FIG. 11. Buttons 224 allow a user to quickly move along electronic document tree 240 . Using buttons 220 and 228 , a user can insert images and documents, respectively, that may have been missed in the initial copying. Using buttons 230 and 232 , a user can change any document or delete any document respectively. The index to any PPB can be changed at button 234 and pages may be split at button 236 . Splitting a page allows a user to separate pages that were fed into the scanner together. The application also displays the image 222 of the page currently being viewed, which image may be of the entire document or a portion thereof. In document view at FIG. 13, electronic tree is replaced with the particular document being viewed. Rail 256 (similar to rail 198 ) indicate the PPB's in that particular document, although in the preferred embodiment, the PPBs cannot be changed in the page-level QC view. The user can refresh data at button 242 to reflect changes being made. The user may scroll through the images of the pages with button 246 , delete an image with button 248 , replace an image with a different image at button 250 and rotate an image with button 252 . Button 244 ends a QC session. Button 254 allows a user to zoom in on the image of a page so as to more easily view details from that page.
[0044] IQC is designed to correspond with the I-CAP application by utilizing a touch-screen monitor, in one embodiment. Multiple layers of document organization typically found in paper files are recreated electronically. Users can search, sort, retrieve and view files in the same manner as opening a box of paper documents.
[0045] The graphical icons display boxes, redwelds (expandable, red rope accordion folders), manila folders, book binding and documents grouped by rubber-bands, binder clips, paperclips, or staples. As illustrated in FIGS. 11 - 13 , the DIT gives users an electronic view of a box of documents similar to physically opening a box of paper documents. They may either surf through by the smallest document level or they may go directly to a box, folder, document or page by simply touching the desired icons in the overhead view. The DIT may utilize graphics familiar to those that handle voluminous amounts of paper files. Like I-CAP, there is no need for a keyboard or mouse to operate this application.
[0046] Since traditional imaging software typically captures only the smallest document level, users do not get the organizational benefit that hard files or the IDCP offer. Users have to hunt for the first page of the file they are looking for. The present invention gives users the ability to go directly to the desired folder. They do not need to surf through the pages at the document level.
[0047] [0047]FIG. 15 illustrates yet another screen capture 276 of the present invention relating to the process of orders out 300 . The user selects a job at area 262 . Tab bar 274 lists the various processing options available to the user for all jobs. Area 278 illustrates that the job may be preprocessed, built into loadfiles, edited as loadfiles, burned or exported. Area 280 shows the various options under preprocessing.
[0048] IPA is the print application which also implements, in the preferred embodiment, a touch-screen monitor. Photocopy operational systems have relied on having the stack of documents being copied present in order to recreate PPB's in the copy sets. Copy machines, at most, can only generate staples and no other PPB's. Traditional scanning software, using bar coded sheets, could capture PPB information but reassembling documents require printing projects and along the way printing the bar coded sheets to signify where PPB's should be inserted. This method requires a person to sit and look for bar coded sheets after the document stack has been printed out.
[0049] Additionally, a complete set of documents may be assembled anywhere in the world. By use of the internet, a disk or other medium containing the information from the scanned job, a user can print and assemble a set of documents. This is possible regardless of whether the original documents or another physical copy of the documents are present where the new set is desired.
[0050] A third aspect of the present invention is called ILM 1006, the Interactive Live Information Management System. This is a management console that every copy/scanning project uses to be introduced into the software. This application will manage all the projects deadlines, assign copy sections, track progress, track productivity and display live updates of metrics for time clock, productivity, revenue, and labor expense. The management console will also store, search and retrieve signed invoices for collection personnel and electronically maintain the industries machine service log for the management personnel.
[0051] An aspect of workflow management 1008 is an image printing application that will queue the machine operator when a PPB needs to be inserted into the printed documents. The present invention sends print jobs to a digital copier by the lowest level page break (staples or loose pages). When a PPB needs to be inserted the software application stops the copy machine and will alert the user to insert the corresponding page break. The user will insert the appropriate page break and then press a continue button to print the next batch of page breaks. At the end of the print job, the operator will have a copy set of documents that are assembled with physical page breaks exactly like the originals.
[0052] Alternatively, IPA can accurately queue the machine operator to insert every level of PPB. The photocopy machine will print the copy sets and automatically insert staples. Every additional level of PPB will momentarily stop the machine and then display a message of which PPB to insert and where it begins and ends. Additionally, IPA will display project instructions on the application interface.
[0053] ILM combines order management, productivity reporting, employee time clock management and document post production processing which are directly linked to the machines that are generating revenues. ILM attempts to automate every reporting, labeling, data entry, and tracking task. When picking up orders, vendors can have handheld devices to take instructions. Upon arrival at the copy facility, job instructions may be electronically beamed into the order management system. Various information about the job such as client name, delivery address, due dates and times, number of boxes, estimated number of copies and other special handling instructions are entered into the software. Managers could then electronically section off jobs and automatically print section identification sheet instead of writing them. Since order processed on digital scanners, no production tracking sheets need to be printed or filled out. Data for copy orders is captured automatically and invoices can be generated without manual calculations or accessing a separate computer applications. After orders are delivered and invoices are signed, vendors may access signed invoices during collection efforts.
[0054] Generating reports from data that is continually collected from the scanning and copy machines will provide up to the minute productivity reporting and client usage reports. Implementing employee time clock will complete all the metrics needed to calculate reports on every measurable indicator of business performance such as employee productivity, revenue generated and rate of income, and labor percentage with respect to revenue generated. FIG. 16 illustrates an example of report 282 of the present invention.
[0055] While the invention has been described with respect to certain preferred embodiments, as will be appreciated by those skilled in the art, it is to be understood that the invention is capable of numerous changes, modifications and rearrangements, and such changes, modifications and rearrangements are intended to be covered by the following claims. Also, in the following claims, those elements which do not include the words “means for” are intended not to be interpreted under 35 U.S.C. §112¶6.
|
A computer-aided system and method for capturing an accurate representation of multiple documents in a computer memory, and for managing a document capture workflow. The method includes enabling a user to view an electronic document image tree representing the documents. The method for managing document capture workflow includes obtaining job information, capturing the documents and processing the document capture job.
| 6
|
GENERAL
The research culminating in this invention was conducted, in part, under contract DAAK20-82-C-0384 with the U.S. Army Electronics Research and Development Command, Fort Monmouth, N.J., pursuant to which contract the Government possesses certain property rights in said invention.
This is a continuation of co-pending application Ser. No. 588,894, filed on Mar. 12, 1984, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a blue phosphor for use in thin-film electroluminescent (TFEL) devices such as electronically-controlled matrix display panels, the blue phosphor comprising a strontium sulphide (SrS) host material doped with cerium fluoride (CeF 3 ) in a concentration sufficient to provide a significant source of visible light photons.
There has been a need for the development of an efficient blue light phosphor for use in TFEL devices. While efficient phosphors for the other primary colors have been developed for solid-state TFEL devices, the brightest TFEL blue phosphor heretofore known is a zinc sulphide host material doped with thulium fluoride (ZnS:TmF 3 ) which has a brightness of 0.33 foot lamberts (fL) at 1 kHz drive excitation. In addition to the fact that the eye is relatively insensitive to the blue part of the visible light spectrum, an additional factor which has rendered efficient solid-state blue emitters so difficult to develop is the large energy transfer required for their excitation because so much of the energy is dissipated in other competing lower energy channels such as optical phonons, donor-acceptor pairs, or lower energy atomic transitions before the blue center is excited. Without an efficient blue phosphor, full-color TFEL display panels, usable in room-light environments, have not been practical.
The use of SrS and other alkaline earth sulphides such as CaS and BaS as host materials for luminescent phosphors, such as those used in powder electroluminescent devices, is disclosed by A. Vecht et al. in "DCEL Dot Matrix Displays in a Range of Colors," Digest of the 1980 Society for Information Display International Symposium, pp. 110-111, and also in Highton and Vecht's U.S. Pat. No. 4,365,184. In addition, the following references describe CRT blue or other primary color powder phosphors using strontium sulphide or other alkaline earth sulphide phosphors:
W. Lehman, "Alkaline Earth Sulfide Phosphors Activated by Copper, Silver, and Gold," J. Electrochem Soc. 117, p. 1389 (1970);
W. Lehman, "On the Optimum Efficiency of Cathodoluminescence of Inorganic Phosphors," J. Electrochem Soc. 118, p. 1164 (1974);
W. Lehman and F. M. Ryan, "Cathodoluminescence of CaS:Ce and CaS:Eu Phosphors," J. Electrochem Soc. 118, p. 477 (1971).
The work by these prior investigators established that SrS, together with CaS, are efficient phosphor hosts in powder form for use in DC-excited and cathodoluminescent applications, but, because of the inherent differences with solid-state TFEL devices, as regards their respective excitation mechanism and structure, no direct correlation could be made or inferred that SrS would likewise be an efficient host material for an AC-excited blue phosphor TFEL device.
SUMMARY OF THE INVENTION
This invention relates to the use of SrS as a host for a blue phosphor TFEL device. More specifically, the invention is directed to a highly efficient AC-excited TFEL blue phosphor comprised of SrS doped with cerium fluoride (CeF 3 ). TFEL devices of the SrS:CeF 3 composition described were prepared by co-evaporation of the host and emitter materials onto a substrate, care being taken to minimize the level of impurities in the deposited films. After deposition the laminar device containing the deposited host-emitter layer and, in some embodiments, sandwiching ZnS electron-injection layers, are heat treated at 600° C. or above to crystalize the structure.
The foregoing and other objectives, features and advantages of the present invention will be more readily understood upon consideration of the following detailed description of the invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FlG. 1 is a schematic representation of a three-layer TFEL device made according to the principles of the present invention.
FIG. 2 is a schematic representation of a modified embodiment of the TFEL device depicted in FIG. 1 which includes an additional pair of electron-injection layers sandwiching the host-emitter layer.
FlG. 3 is a luminance vs. applied voltage curve, at a drive frequency of 1 kHz, for an exemplary SrS:CeF 3 blue phosphor TFEL device of the type depicted in FIG. 2.
FIG. 4 is an emission spectrum plot of an exemplary SrS:CeF 3 blue phosphor TFEL device of the type depicted in FIG. 2.
FIG. 5 is an emission spectrum plot of an exemplary SrS:CeF 3 blue phosphor TFEL device of the type depicted in FIG. 2 and having a significant impurity level, the plot, when compared with that of FIG. 4, illustrating the changes in the emission spectrum which occur as a result of such impurity level.
FIG. 6 is two curves of luminance vs. applied voltage for exemplary SrS:CeF 3 blue phosphor TFEL devices of the type depicted in FIG. 2 showing the effects of different levels of heat treatments on device performance characteristics.
DETAILED DESCRIPTION OF THE INVENTION
In its standard form a conventional state-of-the-art TFEL device structure, such as that depicted in Inazaki et al. U.S. Pat. No. 3,946,371, comprises five layers, namely, a pair of insulating layers sandwiching an electroluminescent phosphor layer, and a pair of electrodes sandwiching the insulating layers. The entire laminar structure is being supported on a substrate of glass or other transparent material, with the TFEL panel being driven by a source of alternating electrical polarity. In FIG. 1 such a structure is shown with the phosphor element being the SrS:CeF 3 blue phosphor of the present invention.
An improvement to the aforedescribed five-layer structure is accomplished by providing a pair of thin-film ZnS layers intermediate the phosphor layer and the sandwiching insulation layers. These additional intermediate layers serve as carrier injection layers to augment the supply of available carriers, modify the threshold voltage, and change the energy distribution of the charge carriers, thereby increasing the amount of visible light emitted from the phosphor layer. This modified TFEL structure, with the SrS:CeF 3 blue phosphor of the present invention included, is illustrated in FIG. 2.
Experimental investigation has demonstrated that, in a TFEL device of the type described, utilizing SrS as the host matter and a CeF 3 dopant as an emitter produces a blue phosphor which is significantly brighter and more efficient than any previously known to the art.
EXAMPLE 1
A SrS:CeF 3 layer for a TFEL device of the configuration illustrated in FIG. 1 was produced onto a 2-inch by 2-inch substrate having a indium tin oxide transparent electrode layer thereon. Next, an aluminum oxide (Al 2 O 3 ) insulating layer of 2500 Å thickness was deposited onto a one-inch-square area. The SrS host material was deposited in vacuo by electron beam evaporation and the CeF 3 dopant was co-deposited by evaporation from a resistance-heated thermal source. The host was deposited at a rate of 6 Å/sec until a film thickness of 5000 Å was achieved. The dopant was co-deposited with the host material at an evaporation rate 0.23% (about 1/400) of the evaporation rate of the latter. The thickness of the host film layer was measured during deposition by both an optical interference monitor and a crystal rate monitor. After the deposition of the phosphor layer was completed, a second insulation layer of aluminum oxide (Al 2 O 3 ) having a thickness of 2500 Å was formed to sandwich the phosphor layer. Finally, an aluminum electrode layer of 1000 Å thickness was deposited to complete the TFEL structure.
EXAMPLE 2
A TFEL device of the configuration illustrated in FIG. 2 was produced by adding, to the SrS:CeF 3 phosphor layer formed in accordance with the process described in reference to Example 1, a pair of sandwiching thin-film carrier injection layers of ZnS material. These layers, which are intermediate the phosphor layer and the respective Al 2 O 3 insulation layers, Were formed to 1000 Å thickness by thermal deposition at a rate of 10 Å/second.
During the depositions of the thin-film layers the substrate was held at 250° C., after deposition was completed, the resultant TFEL structure was annealed in vacuo to promote a high degree of crystalization by bringing the temperature of the structure to above 600° C. and holding it at such elevated temperature for a period of one hour. (Heat treatment was found to be critical to the performance as specimens which were annealed at temperatures less than 600° C. exhibited but minimal light emission.) On the other hand, above 600° C., TFEL devices of the type described which were annealed at higher temperatures exhibited significantly greater brightness levels.
Because of the hydrophilic nature of the SrS material and its tendency to convert from the sulphide to sulphate and oxide, repeated firings of the sulphate in H 2 S and careful handling was required once the material was produced. In addition, the SrS source material, as well as the deposited film, were checked for the presence of impurities, such as as SrSO 4 and SrO, by means of X-ray diffaction.
Of the runs of SrS:CeF 3 blue phosphor specimens prepared in accordance with the procedure of these two examples, the most efficient one, which was of the configuration depicted in FIG. 1, exhibited, at a 1 kHz drive frequency, a luminance of 24 fL and an efficiency of 0.39 lumens/watt.
On the other hand, the inclusion of the intermediate ZnS carrier injection layers measurably improved brightness performance. Of the specimens having the configuration depicted in FIG. 2, the best exhibited a luminance of 45 fL (i.e., two times brighter) and an efficiency of 0.13 (one-third as efficient).
The efficiency of the phosphor was found to decrease as the stoichiometry of the SrS was altered. Also, the relative concentration of dopant to host material in the phosphor affected blue light emissivity, and, for effective performance, the relative concentration level should be less than about 2%.
FIGS. 3 and 4 depict performance characteristics of an exemplary SrS:CeF 3 blue phosphor TFEL device made in accordance with Example 2 and configured as in FIG. 2. At an applied drive frequency of 1 kHz, luminance increases with applied voltage, reaching 45 fL at 210 volts. The emission spectrum exhibits a fairly broad peak near 470 nanometers (nm).
As mentioned earlier, the performance of the TFEL device was found to be profoundly influenced by the amount of impurity present in the phosphor and the level of crystallization of the deposited film, as determined by the degree of heat treatment. FIGS. 5 and 6 illustrate these observed phenomena. In FIG. 5 the emission spectrum of an SrS:CeF 3 TFEL device is shown in which the phosphor film was intentionally deposited in a partial pressure of oxygen, rather than in vacuum. The spectrum of the resulting "contaminated" phosphor exhibits peaks near 500 nm, 600 nm and 660 nm, and the emission appears decidedly more green than blue. FIG. 6 shows the luminance vs. applied voltage curve, at 1 kHz drive frequency for exemplary SrS:CeF 3 TFEL devices, of the construction depicted in FIG. 2, annealed at two different temperatures. The specimen with the 700° C. anneal temperature exhibited luminance several times brighter than the one having the 650° C. anneal temperature. The higher anneal temperature produces more complete crystallization of the film grain structure, and this has been corroborated with transmission electron microscopy studies.
The terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow.
|
A highly efficient, AC-excited, blue light-emitting phosphor for solid-state thin-film electro-luminescent (TFEL) devices is comprised of strontium sulphide (SrS) host material doped with cerium fluoride (CeF 3 ) acting as an emitter providing a source of photons. The blue SrS:CeF 3 phosphor is about one hundred times brighter than the brightest zinc sulphide/thulium fluoride (ZnS:TmF 3 ) blue phosphor heretofore known. To increase brightness level, at some loss of energy efficiency, electron-injection layers of zinc sulfide (ZnS) are placed on either side of the SrS:CeF 3 layer in the TFEL device.
| 7
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of U.S. Provisional Patent Application No. 60/886,144, filed on Jan. 23, 2007, the contents of which are herein incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates to the isolation and production of cancerous disease modifying antibodies (CDMAB) and to the use of these CDMAB alone or in combination with one or more CDMAB/chemotherapeutic agents in therapeutic and diagnostic processes. The invention further relates to binding assays which utilize the CDMAB of the instant invention.
BACKGROUND OF THE INVENTION
[0003] Monoclonal Antibodies as Cancer Therapy: Each individual who presents with cancer is unique and has a cancer that is as different from other cancers as that person's identity. Despite this, current therapy treats all patients with the same type of cancer, at the same stage, in the same way. At least 30 percent of these patients will fail the first line therapy, thus leading to further rounds of treatment and the increased probability of treatment failure, metastases, and ultimately, death. A superior approach to treatment would be the customization of therapy for the particular individual. The only current therapy which lends itself to customization is surgery. Chemotherapy and radiation treatment cannot be tailored to the patient, and surgery by itself, in most cases is inadequate for producing cures.
[0004] With the advent of monoclonal antibodies, the possibility of developing methods for customized therapy became more realistic since each antibody can be directed to a single epitope. Furthermore, it is possible to produce a combination of antibodies that are directed to the constellation of epitopes that uniquely define a particular individual's tumor.
[0005] Having recognized that a significant difference between cancerous and normal cells is that cancerous cells contain antigens that are specific to transformed cells, the scientific community has long held that monoclonal antibodies can be designed to specifically target transformed cells by binding specifically to these cancer antigens; thus giving rise to the belief that monoclonal antibodies can serve as “Magic Bullets” to eliminate cancer cells. However, it is now widely recognized that no single monoclonal antibody can serve in all instances of cancer, and that monoclonal antibodies can be deployed, as a class, as targeted cancer treatments. Monoclonal antibodies isolated in accordance with the teachings of the instantly disclosed invention have been shown to modify the cancerous disease process in a manner which is beneficial to the patient, for example by reducing the tumor burden, and will variously be referred to herein as cancerous disease modifying antibodies (CDMAB) or “anti-cancer” antibodies.
[0006] At the present time, the cancer patient usually has few options of treatment. The regimented approach to cancer therapy has produced improvements in global survival and morbidity rates. However, to the particular individual, these improved statistics do not necessarily correlate with an improvement in their personal situation.
[0007] Thus, if a methodology was put forth which enabled the practitioner to treat each tumor independently of other patients in the same cohort, this would permit the unique approach of tailoring therapy to just that one person. Such a course of therapy would, ideally, increase the rate of cures, and produce better outcomes, thereby satisfying a long-felt need.
[0008] Historically, the use of polyclonal antibodies has been used with limited success in the treatment of human cancers. Lymphomas and leukemias have been treated with human plasma, but there were few prolonged remission or responses. Furthermore, there was a lack of reproducibility and there was no additional benefit compared to chemotherapy. Solid tumors such as breast cancers, melanomas and renal cell carcinomas have also been treated with human blood, chimpanzee serum, human plasma and horse serum with correspondingly unpredictable and ineffective results.
[0009] There have been many clinical trials of monoclonal antibodies for solid tumors. In the 1980s there were at least four clinical trials for human breast cancer which produced only one responder from at least 47 patients using antibodies against specific antigens or based on tissue selectivity. It was not until 1998 that there was a successful clinical trial using a humanized anti-Her2/neu antibody (Herceptin®) in combination with CISPLATIN. In this trial 37 patients were assessed for responses of which about a quarter had a partial response rate and an additional quarter had minor or stable disease progression. The median time to progression among the responders was 8.4 months with median response duration of 5.3 months.
[0010] Herceptin® was approved in 1998 for first line use in combination with Taxol®. Clinical study results showed an increase in the median time to disease progression for those who received antibody therapy plus Taxol® (6.9 months) in comparison to the group that received Taxol® alone (3.0 months). There was also a slight increase in median survival; 22 versus 18 months for the Herceptin® plus Taxol® treatment arm versus the Taxol® treatment alone arm. In addition, there was an increase in the number of both complete (8 versus 2 percent) and partial responders (34 versus 15 percent) in the antibody plus Taxol® combination group in comparison to Taxol® alone. However, treatment with Herceptin® and Taxol® led to a higher incidence of cardiotoxicity in comparison to Taxol® treatment alone (13 versus 1 percent respectively). Also, Herceptin® therapy was only effective for patients who over express (as determined through immunohistochemistry (IHC) analysis) the human epidermal growth factor receptor 2 (Her2/neu), a receptor, which currently has no known function or biologically important ligand; approximately 25 percent of patients who have metastatic breast cancer. Therefore, there is still a large unmet need for patients with breast cancer. Even those who can benefit from Herceptin® treatment would still require chemotherapy and consequently would still have to deal with, at least to some degree, the side effects of this kind of treatment.
[0011] The clinical trials investigating colorectal cancer involve antibodies against both glycoprotein and glycolipid targets. Antibodies such as 17-1A, which has some specificity for adenocarcinomas, has undergone Phase 2 clinical trials in over 60 patients with only 1 patient having a partial response. In other trials, use of 17-1A produced only 1 complete response and 2 minor responses among 52 patients in protocols using additional cyclophosphamide. To date, Phase III clinical trials of 17-1A have not demonstrated improved efficacy as adjuvant therapy for stage III colon cancer. The use of a humanized murine monoclonal antibody initially approved for imaging also did not produce tumor regression.
[0012] Only recently have there been any positive results from colorectal cancer clinical studies with the use of monoclonal antibodies. In 2004, ERBITUX® was approved for the second line treatment of patients with EGFR-expressing metastatic colorectal cancer who are refractory to irinotecan-based chemotherapy. Results from both a two-arm Phase II clinical study and a single arm study showed that ERBITUX® in combination with irinotecan had a response rate of 23 and 15 percent respectively with a median time to disease progression of 4.1 and 6.5 months respectively. Results from the same two-arm Phase II clinical study and another single arm study showed that treatment with ERBITUX® alone resulted in an 11 and 9 percent response rate respectively with a median time to disease progression of 1.5 and 4.2 months respectively.
[0013] Consequently in both Switzerland and the United States, ERBITUX® treatment in combination with irinotecan, and in the United States, ERBITUX® treatment alone, has been approved as a second line treatment of colon cancer patients who have failed first line irinotecan therapy. Therefore, like Herceptin®, treatment in Switzerland is only approved as a combination of monoclonal antibody and chemotherapy. In addition, treatment in both Switzerland and the US is only approved for patients as a second line therapy. Also, in 2004, AVASTIN® was approved for use in combination with intravenous 5-fluorouracil-based chemotherapy as a first line treatment of metastatic colorectal cancer. Phase III clinical study results demonstrated a prolongation in the median survival of patients treated with AVASTIN® plus 5-fluorouracil compared to patients treated with 5-fluourouracil alone (20 months versus 16 months respectively). However, again like Herceptin® and ERBITUX®, treatment is only approved as a combination of monoclonal antibody and chemotherapy.
[0014] There also continues to be poor results for lung, brain, ovarian, pancreatic, prostate, and stomach cancer. The most promising recent results for non-small cell lung cancer came from a Phase II clinical trial where treatment involved a monoclonal antibody (SGN-15; dox-BR96, anti-Sialyl-LeX) conjugated to the cell-killing drug doxorubicin in combination with the chemotherapeutic agent TAXOTERE®. TAXOTERE® is the only FDA approved chemotherapy for the second line treatment of lung cancer. Initial data indicate an improved overall survival compared to TAXOTERE® alone. Out of the 62 patients who were recruited for the study, two-thirds received SGN-15 in combination with TAXOTERE® while the remaining one-third received TAXOTERE® alone. For the patients receiving SGN-15 in combination with TAXOTERE®, median overall survival was 7.3 months in comparison to 5.9 months for patients receiving TAXOTERE® alone. Overall survival at 1 year and 18 months was 29 and 18 percent respectively for patients receiving SNG-15 plus TAXOTERE® compared to 24 and 8 percent respectively for patients receiving TAXOTERE® alone. Further clinical trials are planned.
[0015] Preclinically, there has been some limited success in the use of monoclonal antibodies for melanoma. Very few of these antibodies have reached clinical trials and to date none have been approved or demonstrated favorable results in Phase III clinical trials.
[0016] The discovery of new drugs to treat disease is hindered by the lack of identification of relevant targets among the products of 30,000 known genes that could contribute to disease pathogenesis. In oncology research, potential drug targets are often selected simply due to the fact that they are over-expressed in tumor cells. Targets thus identified are then screened for interaction with a multitude of compounds. In the case of potential antibody therapies, these candidate compounds are usually derived from traditional methods of monoclonal antibody generation according to the fundamental principles laid down by Kohler and Milstein (1975, Nature, 256, 495-497, Kohler and Milstein). Spleen cells are collected from mice immunized with antigen (e.g. whole cells, cell fractions, purified antigen) and fused with immortalized hybridoma partners. The resulting hybridomas are screened and selected for secretion of antibodies which bind most avidly to the target. Many therapeutic and diagnostic antibodies directed against cancer cells, including Herceptin® and RITUXIMAB, have been produced using these methods and selected on the basis of their affinity. The flaws in this strategy are two-fold. Firstly, the choice of appropriate targets for therapeutic or diagnostic antibody binding is limited by the paucity of knowledge surrounding tissue specific carcinogenic processes and the resulting simplistic methods, such as selection by overexpression, by which these targets are identified. Secondly, the assumption that the drug molecule that binds to the receptor with the greatest affinity usually has the highest probability for initiating or inhibiting a signal may not always be the case.
[0017] Despite some progress with the treatment of breast and colon cancer, the identification and development of efficacious antibody therapies, either as single agents or co-treatments, has been inadequate for all types of cancer.
Prior Patents:
[0018] U.S. Pat. No. 5,750,102 discloses a process wherein cells from a patient's tumor are transfected with MHC genes which may be cloned from cells or tissue from the patient. These transfected cells are then used to vaccinate the patient.
[0019] U.S. Pat. No. 4,861,581 discloses a process comprising the steps of obtaining monoclonal antibodies that are specific to an internal cellular component of neoplastic and normal cells of the mammal but not to external components, labeling the monoclonal antibody, contacting the labeled antibody with tissue of a mammal that has received therapy to kill neoplastic cells, and determining the effectiveness of therapy by measuring the binding of the labeled antibody to the internal cellular component of the degenerating neoplastic cells. In preparing antibodies directed to human intracellular antigens, the patentee recognizes that malignant cells represent a convenient source of such antigens.
[0020] U.S. Pat. No. 5,171,665 provides a novel antibody and method for its production. Specifically, the patent teaches formation of a monoclonal antibody which has the property of binding strongly to a protein antigen associated with human tumors, e.g. those of the colon and lung, while binding to normal cells to a much lesser degree.
[0021] U.S. Pat. No. 5,484,596 provides a method of cancer therapy comprising surgically removing tumor tissue from a human cancer patient, treating the tumor tissue to obtain tumor cells, irradiating the tumor cells to be viable but non-tumorigenic, and using these cells to prepare a vaccine for the patient capable of inhibiting recurrence of the primary tumor while simultaneously inhibiting metastases. The patent teaches the development of monoclonal antibodies which are reactive with surface antigens of tumor cells. As set forth at col. 4, lines 45 et seq., the patentees utilize autochthonous tumor cells in the development of monoclonal antibodies expressing active specific immunotherapy in human neoplasia.
[0022] U.S. Pat. No. 5,693,763 teaches a glycoprotein antigen characteristic of human carcinomas and not dependent upon the epithelial tissue of origin.
[0023] U.S. Pat. No. 5,783,186 is drawn to Anti-Her2 antibodies which induce apoptosis in Her2 expressing cells, hybridoma cell lines producing the antibodies, methods of treating cancer using the antibodies and pharmaceutical compositions including said antibodies.
[0024] U.S. Pat. No. 5,849,876 describes new hybridoma cell lines for the production of monoclonal antibodies to mucin antigens purified from tumor and non-tumor tissue sources.
[0025] U.S. Pat. No. 5,869,268 is drawn to a method for generating a human lymphocyte producing an antibody specific to a desired antigen, a method for producing a monoclonal antibody, as well as monoclonal antibodies produced by the method. The patent is particularly drawn to the production of an anti-HD human monoclonal antibody useful for the diagnosis and treatment of cancers.
[0026] U.S. Pat. No. 5,869,045 relates to antibodies, antibody fragments, antibody conjugates and single-chain immunotoxins reactive with human carcinoma cells. The mechanism by which these antibodies function is two-fold, in that the molecules are reactive with cell membrane antigens present on the surface of human carcinomas, and further in that the antibodies have the ability to internalize within the carcinoma cells, subsequent to binding, making them especially useful for forming antibody-drug and antibody-toxin conjugates. In their unmodified form the antibodies also manifest cytotoxic properties at specific concentrations.
[0027] U.S. Pat. No. 5,780,033 discloses the use of autoantibodies for tumor therapy and prophylaxis. However, this antibody is an antinuclear autoantibody from an aged mammal. In this case, the autoantibody is said to be one type of natural antibody found in the immune system. Because the autoantibody comes from “an aged mammal”, there is no requirement that the autoantibody actually comes from the patient being treated. In addition the patent discloses natural and monoclonal antinuclear autoantibody from an aged mammal, and a hybridoma cell line producing a monoclonal antinuclear autoantibody.
SUMMARY OF THE INVENTION
[0028] This application utilizes methodology for producing patient specific anti-cancer antibodies taught in the U.S. Pat. No. 6,180,357 patent for isolating hybridoma cell lines which encode for cancerous disease modifying monoclonal antibodies. These antibodies can be made specifically for one tumor and thus make possible the customization of cancer therapy. Within the context of this application, anti-cancer antibodies having either cell-killing (cytotoxic) or cell-growth inhibiting (cytostatic) properties will hereafter be referred to as cytotoxic. These antibodies can be used in aid of staging and diagnosis of a cancer, and can be used to treat tumor metastases. These antibodies can also be used for the prevention of cancer by way of prophylactic treatment. Unlike antibodies generated according to traditional drug discovery paradigms, antibodies generated in this way may target molecules and pathways not previously shown to be integral to the growth and/or survival of malignant tissue. Furthermore, the binding affinities of these antibodies are suited to requirements for initiation of the cytotoxic events that may not be amenable to stronger affinity interactions. Also, it is within the purview of this invention to conjugate standard chemotherapeutic modalities, e.g. radionuclides, with the CDMAB of the instant invention, thereby focusing the use of said chemotherapeutics. The CDMAB can also be conjugated to toxins, cytotoxic moieties, enzymes e.g. biotin conjugated enzymes, cytokines, interferons, target or reporter moieties or hematogenous cells, thereby forming an antibody conjugate. The CDMAB can be used alone or in combination with one or more CDMAB/chemotherapeutic agents.
[0029] The prospect of individualized anti-cancer treatment will bring about a change in the way a patient is managed. A likely clinical scenario is that a tumor sample is obtained at the time of presentation, and banked. From this sample, the tumor can be typed from a panel of pre-existing cancerous disease modifying antibodies. The patient will be conventionally staged but the available antibodies can be of use in further staging the patient. The patient can be treated immediately with the existing antibodies, and a panel of antibodies specific to the tumor can be produced either using the methods outlined herein or through the use of phage display libraries in conjunction with the screening methods herein disclosed. All the antibodies generated will be added to the library of anti-cancer antibodies since there is a possibility that other tumors can bear some of the same epitopes as the one that is being treated. The antibodies produced according to this method may be useful to treat cancerous disease in any number of patients who have cancers that bind to these antibodies.
[0030] In addition to anti-cancer antibodies, the patient can elect to receive the currently recommended therapies as part of a multi-modal regimen of treatment. The fact that the antibodies isolated via the present methodology are relatively non-toxic to non-cancerous cells allows for combinations of antibodies at high doses to be used, either alone, or in conjunction with conventional therapy. The high therapeutic index will also permit re-treatment on a short time scale that should decrease the likelihood of emergence of treatment resistant cells.
[0031] If the patient is refractory to the initial course of therapy or metastases develop, the process of generating specific antibodies to the tumor can be repeated for re-treatment. Furthermore, the anti-cancer antibodies can be conjugated to red blood cells obtained from that patient and re-infused for treatment of metastases. There have been few effective treatments for metastatic cancer and metastases usually portend a poor outcome resulting in death. However, metastatic cancers are usually well vascularized and the delivery of anti-cancer antibodies by red blood cells can have the effect of concentrating the antibodies at the site of the tumor. Even prior to metastases, most cancer cells are dependent on the host's blood supply for their survival and an anti-cancer antibody conjugated to red blood cells can be effective against in situ tumors as well. Alternatively, the antibodies may be conjugated to other hematogenous cells, e.g. lymphocytes, macrophages, monocytes, natural killer cells, etc.
[0032] There are five classes of antibodies and each is associated with a function that is conferred by its heavy chain. It is generally thought that cancer cell killing by naked antibodies are mediated either through antibody dependent cellular cytotoxicity or complement dependent cytotoxicity. For example murine IgM and IgG2a antibodies can activate human complement by binding the C-1 component of the complement system thereby activating the classical pathway of complement activation which can lead to tumor lysis. For human antibodies the most effective complement activating antibodies are generally IgM and IgG1. Murine antibodies of the IgG2a and IgG3 isotype are effective at recruiting cytotoxic cells that have Fc receptors which will lead to cell killing by monocytes, macrophages, granulocytes and certain lymphocytes. Human antibodies of both the IgG1 and IgG3 isotype mediate ADCC.
[0033] The cytotoxicity mediated through the Fc region requires the presence of effector cells and their corresponding receptors, or proteins e.g. NK cells, complement, and T-cells, respectively. In the absence of these effector mechanisms, the Fc portion of an antibody is inert. The Fc portion of an antibody may confer properties that affect the pharmacokinetics of an antibody in vivo, but in vitro this is not operative.
[0034] The cytotoxicity assays under which we test the antibodies do not have any of the effector mechanisms present, and are carried out in vitro. These assays do not have effector cells (NK, Macrophages, or T-cells) or complement present. Since these assays are completely defined by what is added together, each component can be characterized. The assays used herein contain only target cells, media and sera. The target cells do not have effector functions since they are cancer cells or fibroblasts. Without exogenous cells which have effector function properties there is no cellular elements that have this function. The media does not contain complement or any cells. The sera used to support the growth of the target cells do not have complement activity as disclosed by the vendors. Furthermore, in our own labs we have verified the absence of complement activity in the sera used. Therefore, our work evidences the fact that the effects of the antibodies are due entirely to the effects of the antigen binding which is mediated through the Fab. Effectively, the target cells are seeing and interacting with only the Fab, since they do not have receptors for the Fc. Although, the hybridoma is secreting complete immunoglobulin which was tested with the target cells, the only part of the immunoglobulin that interacts with the cells are the Fab, which act as antigen binding fragments.
[0035] With respect to the instantly claimed antibodies and antigen binding fragments, the application, as filed, has demonstrated cellular cytotoxicity as evidenced by the data in Table 1. As pointed out above, and as herein confirmed via objective evidence, this effect was entirely due to binding by the Fab to the tumor cells.
[0036] Ample evidence exists in the art of antibodies mediating cytotoxicity due to direct binding of the antibody to the target antigen independent of effector mechanisms recruited by the Fc. The best evidence for this is in vitro experiments which do not have supplemental cells, or complement (to formally exclude those mechanisms). These types of experiments have been carried out with complete immunoglobulin, or with antigen binding fragments such as F(ab)′2 fragments. In these types of experiments, antibodies or antigen binding fragments can directly induce apoptosis of target cells such as in the case of anti-Her2 and anti-EGFR antibodies, both of which have antibodies that are approved by the US FDA for marketing in cancer therapy.
[0037] Another possible mechanism of antibody mediated cancer killing may be through the use of antibodies that function to catalyze the hydrolysis of various chemical bonds in the cell membrane and its associated glycoproteins or glycolipids, so-called catalytic antibodies.
[0038] There are three additional mechanisms of antibody-mediated cancer cell killing. The first is the use of antibodies as a vaccine to induce the body to produce an immune response against the putative antigen that resides on the cancer cell. The second is the use of antibodies to target growth receptors and interfere with their function or to down regulate that receptor so that its function is effectively lost. The third is the effect of such antibodies on direct ligation of cell surface moieties that may lead to direct cell death, such as ligation of death receptors such as TRAIL R1 or TRAIL R2, or integrin molecules such as alpha V beta 3 and the like.
[0039] The clinical utility of a cancer drug is based on the benefit of the drug under an acceptable risk profile to the patient. In cancer therapy survival has generally been the most sought after benefit, however there are a number of other well-recognized benefits in addition to prolonging life. These other benefits, where treatment does not adversely affect survival, include symptom palliation, protection against adverse events, prolongation in time to recurrence or disease-free survival, and prolongation in time to progression. These criteria are generally accepted and regulatory bodies such as the U.S. Food and Drug Administration (F.D.A.) approve drugs that produce these benefits (Hirschfeld et al. Critical Reviews in Oncology/Hematology 42:137-143 2002). In addition to these criteria it is well recognized that there are other endpoints that may presage these types of benefits. In part, the accelerated approval process granted by the U.S. F.D.A. acknowledges that there are surrogates that will likely predict patient benefit. As of year-end 2003, there have been sixteen drugs approved under this process, and of these, four have gone on to full approval, i.e., follow-up studies have demonstrated direct patient benefit as predicted by surrogate endpoints. One important endpoint for determining drug effects in solid tumors is the assessment of tumor burden by measuring response to treatment (Therasse et al. Journal of the National Cancer Institute 92(3):205-216 2000). The clinical criteria (RECIST criteria) for such evaluation have been promulgated by Response Evaluation Criteria in Solid Tumors Working Group, a group of international experts in cancer. Drugs with a demonstrated effect on tumor burden, as shown by objective responses according to RECIST criteria, in comparison to the appropriate control group tend to, ultimately, produce direct patient benefit. In the pre-clinical setting tumor burden is generally more straightforward to assess and document. In that pre-clinical studies can be translated to the clinical setting, drugs that produce prolonged survival in pre-clinical models have the greatest anticipated clinical utility. Analogous to producing positive responses to clinical treatment, drugs that reduce tumor burden in the pre-clinical setting may also have significant direct impact on the disease. Although prolongation of survival is the most sought after clinical outcome from cancer drug treatment, there are other benefits that have clinical utility and it is clear that tumor burden reduction, which may correlate to a delay in disease progression, extended survival or both, can also lead to direct benefits and have clinical impact (Eckhardt et al. Developmental Therapeutics: Successes and Failures of Clinical Trial Designs of Targeted Compounds; ASCO Educational Book, 39 th Annual Meeting, 2003, pages 209-219).
[0040] The present invention describes the development and use of AR91A9.2 identified by its effect in a cytotoxic assay and in an animal model of human cancer. This invention describes reagents that bind specifically to an epitope or epitopes present on the target molecule, and that also have in vitro cytotoxic properties, as a naked antibody, against malignant tumor cells but not normal cells, and which also directly mediate, as a naked antibody, inhibition of tumor growth. A further advance is of the use of anti-cancer antibodies such as this to target tumors expressing cognate antigen markers to achieve tumor growth inhibition, and other positive endpoints of cancer treatment.
[0041] In all, this invention teaches the use of the AR91A9.2 antigen as a target for a therapeutic agent, that when administered can reduce the tumor burden of a cancer expressing the antigen in a mammal. This invention also teaches the use of CDMAB (AR91A9.2), and their derivatives, and antigen binding fragments thereof, and cytotoxicity inducing ligands thereof, to target their antigen to reduce the tumor burden of a cancer expressing the antigen in a mammal. Furthermore, this invention also teaches the use of detecting the AR91A9.2 antigen in cancerous cells that can be useful for the diagnosis, prediction of therapy, and prognosis of mammals bearing tumors that express this antigen.
[0042] Accordingly, it is an objective of the invention to utilize a method for producing cancerous disease modifying antibodies (CDMAB) raised against cancerous cells derived from a particular individual, or one or more particular cancer cell lines, which CDMAB are cytotoxic with respect to cancer cells while simultaneously being relatively non-toxic to non-cancerous cells, in order to isolate hybridoma cell lines and the corresponding isolated monoclonal antibodies and antigen binding fragments thereof for which said hybridoma cell lines are encoded.
[0043] It is an additional objective of the invention to teach cancerous disease modifying antibodies, ligands and antigen binding fragments thereof.
[0044] It is a further objective of the instant invention to produce cancerous disease modifying antibodies whose cytotoxicity is mediated through antibody dependent cellular toxicity.
[0045] It is yet an additional objective of the instant invention to produce cancerous disease modifying antibodies whose cytotoxicity is mediated through complement dependent cellular toxicity.
[0046] It is still a further objective of the instant invention to produce cancerous disease modifying antibodies whose cytotoxicity is a function of their ability to catalyze hydrolysis of cellular chemical bonds.
[0047] A still further objective of the instant invention is to produce cancerous disease modifying antibodies which are useful for in a binding assay for diagnosis, prognosis, and monitoring of cancer.
[0048] Other objects and advantages of this invention will become apparent from the following description wherein are set forth, by way of illustration and example, certain embodiments of this invention.
BRIEF DESCRIPTION OF THE FIGURES
[0049] FIG. 1 compares the percentage cytotoxicity and binding levels of the hybridoma supernatants against cell lines A549, NCI-H23, NCI-H460, MDA-MB-231 and Hs888.Lu.
[0050] FIG. 2 represents binding of AR91A9.2 to cancer and normal cell lines. The data is tabulated to present the mean fluorescence intensity as a fold increase above isotype control.
[0051] FIG. 3 includes representative FACS histograms of AR91A9.2 and anti-EGFR antibodies directed against several cancer and non-cancer cell lines.
[0052] FIG. 4 demonstrates the effect of AR91A9.2 on tumor growth in a prophylactic NCI-H520 lung cancer model. The vertical dashed lines indicate the period during which the antibody was administered. Data points represent the mean +/−SEM.
[0053] FIG. 5 demonstrates the effect of AR91A9.2 on body weight in a prophylactic NCI-H520 lung cancer model. Data points represent the mean +/−SEM.
DETAILED DESCRIPTION OF THE INVENTION
[0054] In general, the following words or phrases have the indicated definition when used in the summary, description, examples, and claims.
[0055] The term “antibody” is used in the broadest sense and specifically covers, for example, single monoclonal antibodies (including agonist, antagonist, and neutralizing antibodies, de-immunized, murine, chimeric or humanized antibodies), antibody compositions with polyepitopic specificity, single-chain antibodies, diabodies, triabodies, immunoconjugates and antibody fragments (see below).
[0056] The term “monoclonal antibody” as used herein refers to an antibody obtained from a population of substantially homogeneous antibodies, i.e., the individual antibodies comprising the population are identical except for possible naturally occurring mutations that may be present in minor amounts. Monoclonal antibodies are highly specific, being directed against a single antigenic site. Furthermore, in contrast to polyclonal antibody preparations which include different antibodies directed against different determinants (epitopes), each monoclonal antibody is directed against a single determinant on the antigen. In addition to their specificity, the monoclonal antibodies are advantageous in that they may be synthesized uncontaminated by other antibodies. The modifier “monoclonal” indicates the character of the antibody as being obtained from a substantially homogeneous population of antibodies, and is not to be construed as requiring production of the antibody by any particular method. For example, the monoclonal antibodies to be used in accordance with the present invention may be made by the hybridoma (murine or human) method first described by Kohler et al., Nature, 256:495 (1975), or may be made by recombinant DNA methods (see, e.g., U.S. Pat. No. 4,816,567). The “monoclonal antibodies” may also be isolated from phage antibody libraries using the techniques described in Clackson et al., Nature, 352:624-628 (1991) and Marks et al., J. Mol. Biol., 222:581-597 (1991), for example.
[0057] “Antibody fragments” comprise a portion of an intact antibody, preferably comprising the antigen-binding or variable region thereof. Examples of antibody fragments include less than full length antibodies, Fab, Fab′, F(ab′) 2 , and Fv fragments; diabodies; linear antibodies; single-chain antibody molecules; single-chain antibodies, single domain antibody molecules, fusion proteins, recombinant proteins and multispecific antibodies formed from antibody fragment(s).
[0058] An “intact” antibody is one which comprises an antigen-binding variable region as well as a light chain constant domain (C L ) and heavy chain constant domains, C H 1, C H 2 and C H 3. The constant domains may be native sequence constant domains (e.g. human native sequence constant domains) or amino acid sequence variant thereof. Preferably, the intact antibody has one or more effector functions.
[0059] Depending on the amino acid sequence of the constant domain of their heavy chains, intact antibodies can be assigned to different “classes”. There are five-major classes of intact antibodies: IgA, IgD, IgE, IgG, and IgM, and several of these may be further divided into “subclasses” (isotypes), e.g., IgG1, IgG2, IgG3, IgG4, IgA, and IgA2. The heavy-chain constant domains that correspond to the different classes of antibodies are called α, δ, ε, γ, and μ, respectively. The subunit structures and three-dimensional configurations of different classes of immunoglobulins are well known.
[0060] Antibody “effector functions” refer to those biological activities attributable to the Fc region (a native sequence Fc region or amino acid sequence variant Fc region) of an antibody. Examples of antibody effector functions include C1q binding; complement dependent cytotoxicity; Fc receptor binding; antibody-dependent cell-mediated cytotoxicity (ADCC); phagocytosis; down regulation of cell surface receptors (e.g. B cell receptor; BCR), etc.
[0061] “Antibody-dependent cell-mediated cytotoxicity” and “ADCC” refer to a cell-mediated reaction in which nonspecific cytotoxic cells that express Fc receptors (FcRs) (e.g. Natural Killer (NK) cells, neutrophils, and macrophages) recognize bound antibody on a target cell and subsequently cause lysis of the target cell. The primary cells for mediating ADCC, NK cells, express FcγRIII only, whereas monocytes express FcγRI, FcγRII and FcγRIII. FcR expression on hematopoietic cells is summarized in Table 3 on page 464 of Ravetch and Kinet, Annu. Rev. Immunol 9:457-92 (1991). To assess ADCC activity of a molecule of interest, an in vitro ADCC assay, such as that described in U.S. Pat. No. 5,500,362 or 5,821,337 may be performed. Useful effector cells for such assays include peripheral blood mononuclear cells (PBMC) and Natural Killer (NK) cells. Alternatively, or additionally, ADCC activity of the molecule of interest may be assessed in vivo, e.g., in a animal model such as that disclosed in Clynes et al. PNAS (USA) 95:652-656 (1998).
[0062] “Effector cells” are leukocytes which express one or more FcRs and perform effector functions. Preferably, the cells express at least FcγRIII and perform ADCC effector function. Examples of human leukocytes which mediate ADCC include peripheral blood mononuclear cells (PBMC), natural killer (NK) cells, monocytes, cytotoxic T cells and neutrophils; with PBMCs and NK cells being preferred. The effector cells may be isolated from a native source thereof, e.g. from blood or PBMCs as described herein.
[0063] The terms “Fc receptor” or “FcR” are used to describe a receptor that binds to the Fc region of an antibody. The preferred FcR is a native sequence human FcR. Moreover, a preferred FcR is one which binds an IgG antibody (a gamma receptor) and includes receptors of the FcγRI, FcγRII, and Fcγ RIII subclasses, including allelic variants and alternatively spliced forms of these receptors. FcγRII receptors include FcγRIIA (an “activating receptor”) and FcγRIIB (an “inhibiting receptor”), which have similar amino acid sequences that differ primarily in the cytoplasmic domains thereof. Activating receptor FcγRIIA contains an immunoreceptor tyrosine-based activation motif (ITAM) in its cytoplasmic domain. Inhibiting receptor FcγRIIB contains an immunoreceptor tyrosine-based inhibition motif (ITIM) in its cytoplasmic domain. (see review M. in Daëron, Annu. Rev. Immunol. 15:203-234 (1997)). FcRs are reviewed in Ravetch and Kinet, Annu. Rev. Immunol 9:457-92 (1991); Capel et al., Immunomethods 4:25-34 (1994); and de Haas et al., J. Lab. Clin. Med. 126:330-41 (1995). Other FcRs, including those to be identified in the future, are encompassed by the term “FcR” herein. The term also includes the neonatal receptor, FcRn, which is responsible for the transfer of maternal IgGs to the fetus (Guyer et al., J. Immunol. 117:587 (1976) and Kim et al., Eur. J. Immunol. 24:2429 (1994)).
[0064] “Complement dependent cytotoxicity” or “CDC” refers to the ability of a molecule to lyse a target in the presence of complement. The complement activation pathway is initiated by the binding of the first component of the complement system (C1q) to a molecule (e.g. an antibody) complexed with a cognate antigen. To assess complement activation, a CDC assay, e.g. as described in Gazzano-Santoro et al., J. Immunol. Methods 202:163 (1996), may be performed.
[0065] The term “variable” refers to the fact that certain portions of the variable domains differ extensively in sequence among antibodies and are used in the binding and specificity of each particular antibody for its particular antigen. However, the variability is not evenly distributed throughout the variable domains of antibodies. It is concentrated in three segments called hypervariable regions both in the light chain and the heavy chain variable domains. The more highly conserved portions of variable domains are called the framework regions (FRs). The variable domains of native heavy and light chains each comprise four FRs, largely adopting a β-sheet configuration, connected by three hypervariable regions, which form loops connecting, and in some cases forming part of, the β-sheet structure. The hypervariable regions in each chain are held together in close proximity by the FRs and, with the hypervariable regions from the other chain, contribute to the formation of the antigen-binding site of antibodies (see Kabat et al., Sequences of Proteins of Immunological Interest, 5th Ed. Public Health Service, National Institutes of Health, Bethesda, Md. (1991)). The constant domains are not involved directly in binding an antibody to an antigen, but exhibit various effector functions, such as participation of the antibody in antibody dependent cellular cytotoxicity (ADCC).
[0066] The term “hypervariable region” when used herein refers to the amino acid residues of an antibody which are responsible for antigen-binding. The hypervariable region generally comprises amino acid residues from a “complementarity determining region” or “CDR” (e.g. residues 24-34 (L1), 50-56 (L2) and 89-97 (L3) in the light chain variable domain and 31-35 (H1), 50-65 (H2) and 95-102 (H3) in the heavy chain variable domain; Kabat et al., Sequences of Proteins of Immunological Interest, 5th Ed. Public Health Service, National Institutes of Health, Bethesda, Md. (1991)) and/or those residues from a “hypervariable loop” (e.g. residues 2632 (L1), 50-52 (L2) and 91-96 (L3) in the light chain variable domain and 26-32 (H1), 53-55 (H2) and 96-101 (H3) in the heavy chain variable domain; Chothia and Lesk J. Mol. Biol. 196:901-917 (1987)). “Framework Region” or “FR” residues are those variable domain residues other than the hypervariable region residues as herein defined. Papain digestion of antibodies produces two identical antigen-binding fragments, called “Fab” fragments, each with a single antigen-binding site, and a residual “Fc” fragment, whose name reflects its ability to crystallize readily. Pepsin treatment yields an F(ab′) 2 fragment that has two antigen-binding sites and is still capable of cross-linking antigen.
[0067] “Fv” is the minimum antibody fragment which contains a complete antigen-recognition and antigen-binding site. This region consists of a dimer of one heavy chain and one light chain variable domain in tight, non-covalent association. It is in this configuration that the three hypervariable regions of each variable domain interact to define an antigen-binding site on the surface of the V H -V L dimer. Collectively, the six hypervariable regions confer antigen-binding specificity to the antibody. However, even a single variable domain (or half of an Fv comprising only three hypervariable regions specific for an antigen) has the ability to recognize and bind antigen, although at a lower affinity than the entire binding site. The Fab fragment also contains the constant domain of the light chain and the first constant domain (CH I) of the heavy chain. Fab′ fragments differ from Fab fragments by the addition of a few residues at the carboxy terminus of the heavy chain CH1 domain including one or more cysteines from the antibody hinge region. Fab′-SH is the designation herein for Fab′ in which the cysteine residue(s) of the constant domains bear at least one free thiol group. F(ab′) 2 antibody fragments originally were produced as pairs of Fab′ fragments which have hinge cysteines between them. Other chemical couplings of antibody fragments are also known.
[0068] The “light chains” of antibodies from any vertebrate species can be assigned to one of two clearly distinct types, called kappa (κ) and lambda (λ), based on the amino acid sequences of their constant domains.
[0069] “Single-chain Fv” or “scFv” antibody fragments comprise the V H and V L domains of antibody, wherein these domains are present in a single polypeptide chain. Preferably, the Fv polypeptide further comprises a polypeptide linker between the V H and V L domains which enables the scFv to form the desired structure for antigen binding. For a review of scFv see Plückthun in The Pharmacology of Monoclonal Antibodies , vol. 113, Rosenburg and Moore eds., Springer-Verlag, New York, pp. 269-315 (1994).
[0070] The term “diabodies” refers to small antibody fragments with two antigen-binding sites, which fragments comprise a variable heavy domain (V H ) connected to a variable light domain (V L ) in the same polypeptide chain (V H -V L ). By using a linker that is too short to allow pairing between the two domains on the same chain, the domains are forced to pair with the complementary domains of another chain and create two antigen-binding sites. Diabodies are described more fully in, for example, EP 404,097; WO 93/11161; and Hollinger et al., Proc. Natl. Acad. Sci. USA, 90:6444-6448 (1993).
[0071] The term “triabodies” or “trivalent trimers” refers to the combination of three single chain antibodies. Triabodies are constructed with the amino acid terminus of a V L or V H domain, i.e., without any linker sequence. A triabody has three Fv heads with the polypeptides arranged in a cyclic, head-to-tail fashion. A possible conformation of the triabody is planar with the three binding sites located in a plane at an angle of 120 degrees from one another. Triabodies can be monospecific, bispecific or trispecific.
[0072] An “isolated” antibody is one which has been identified and separated and/or recovered from a component of its natural environment. Contaminant components of its natural environment are materials which would interfere with diagnostic or therapeutic uses for the antibody, and may include enzymes, hormones, and other proteinaceous or nonproteinaceous solutes. Isolated antibody includes the antibody in situ within recombinant cells since at least one component of the antibody's natural environment will not be present. Ordinarily, however, isolated antibody will be prepared by at least one purification step.
[0073] An antibody “which binds” an antigen of interest is one capable of binding that antigen with sufficient affinity such that the antibody is useful as a therapeutic or diagnostic agent in targeting a cell expressing the antigen. Where the antibody is one which binds the antigenic moiety it will usually preferentially bind that antigenic moiety as opposed to other receptors, and does not include incidental binding such as non-specific Fc contact, or binding to post-translational modifications common to other antigens and may be one which does not significantly cross-react with other proteins. Methods, for the detection of an antibody that binds an antigen of interest, are well known in the art and can include but are not limited to assays such as FACS, cell ELISA and Western blot.
[0074] As used herein, the expressions “cell”, “cell line”, and “cell culture” are used interchangeably, and all such designations include progeny. It is also understood that all progeny may not be precisely identical in DNA content, due to deliberate or inadvertent mutations. Mutant progeny that have the same function or biological activity as screened for in the originally transformed cell are included. It will be clear from the context where distinct designations are intended.
[0075] “Treatment or treating” refers to both therapeutic treatment and prophylactic or preventative measures, wherein the object is to prevent or slow down (lessen) the targeted pathologic condition or disorder. Those in need of treatment include those already with the disorder as well as those prone to have the disorder or those in whom the disorder is to be prevented. Hence, the mammal to be treated herein may have been diagnosed as having the disorder or may be predisposed or susceptible to the disorder.
[0076] The terms “cancer” and “cancerous” refer to or describe the physiological condition in mammals that is typically characterized by unregulated cell growth or death. Examples of cancer include, but are not limited to, carcinoma, lymphoma, blastoma, sarcoma, and leukemia or lymphoid malignancies. More particular examples of such cancers include squamous cell cancer (e.g. epithelial squamous cell cancer), lung cancer including small-cell lung cancer, non-small cell lung cancer, adenocarcinoma of the lung and squamous carcinoma of the lung, cancer of the peritoneum, hepatocellular cancer, gastric or stomach cancer including gastrointestinal cancer, pancreatic cancer, glioblastoma, cervical cancer, ovarian cancer, liver cancer, bladder cancer, hepatoma, breast cancer, colon cancer, rectal cancer, colorectal cancer, endometrial or uterine carcinoma, salivary gland carcinoma, kidney or renal cancer, prostate cancer, vulval cancer, thyroid cancer, hepatic carcinoma, anal carcinoma, penile carcinoma, as well as head and neck cancer.
[0077] A “chemotherapeutic agent” is a chemical compound useful in the treatment of cancer. Examples of chemotherapeutic agents include alkylating agents such as thiotepa and cyclosphosphamide (CYTOXAN™); alkyl sulfonates such as busulfan, improsulfan and piposulfan; aziridines such as benzodopa, carboquone, meturedopa, and uredopa; ethylenimines and methylamelamines including altretamine, triethylenemelamine, triethylenephosphoramide, triethylenethiophosphoramide and trimethylolomelamine; nitrogen mustards such as chlorambucil, chlornaphazine, cholophosphamide, estramustine, ifosfamide, mechlorethamine, mechlorethamine oxide hydrochloride, melphalan, novembichin, phenesterine, prednimustine, trofosfamide, uracil mustard; nitrosureas such as carmustine, chlorozotocin, fotemustine, lomustine, nimustine, ranimustine; antibiotics such as aclacinomysins, actinomycin, authramycin, azaserine, bleomycins, cactinomycin, calicheamicin, carabicin, carnomycin, carzinophilin, chromomycins, dactinomycin, daunorubicin, detorubicin, 6-diazo-5-oxo-L-norleucine, doxorubicin, epirubicin, esorubicin, idarubicin, marcellomycin, mitomycins, mycophenolic acid, nogalamycin, olivomycins, peplomycin, potfiromycin, puromycin, quelamycin, rodorubicin, streptonigrin, streptozocin, tubercidin, ubenimex, zinostatin, zorubicin; anti-metabolites such as methotrexate and 5-fluorouracil (5-FU); folic acid analogues such as denopterin, methotrexate, pteropterin, trimetrexate; purine analogs such as fludarabine, 6-mercaptopurine, thiamiprine, thioguanine; pyrimidine analogs such as ancitabine, azacitidine, 6-azauridine, carmofur, cytarabine, dideoxyuridine, doxifluridine, enocitabine, floxuridine, 5-FU; androgens such as calusterone, dromostanolone propionate, epitiostanol, mepitiostane, testolactone; anti-adrenals such as aminoglutethimide, mitotane, trilostane; folic acid replenisher such as frolinic acid; aceglatone; aldophosphamide glycoside; aminolevulinic acid; amsacrine; bestrabucil; bisantrene; edatraxate; defofamine; demecolcine; diaziquone; elformithine; elliptinium acetate; etoglucid; gallium nitrate; hydroxyurea; lentinan; lonidamine; mitoguazone; mitoxantrone; mopidamol; nitracrine; pentostatin; phenamet; pirarubicin; podophyllinic acid; 2-ethylhydrazide; procarbazine; PSK®; razoxane; sizofuran; spirogermanium; tenuazonic acid; triaziquone; 2,2′,2″-trichlorotriethylamine; urethan; vindesine; dacarbazine; mannomustine; mitobronitol; mitolactol; pipobroman; gacytosine; arabinoside (“Ara-C”); cyclophosphamide; thiotepa; taxanes, e.g. paclitaxel (TAXOL®, Bristol-Myers Squibb Oncology, Princeton, N.J.) and docetaxel (TAXOTERE®, Aventis, Rhone-Poulenc Rorer, Antony, France); chlorambucil; gemcitabine; 6-thioguanine; mercaptopurine; methotrexate; platinum analogs such as cisplatin and carboplatin; vinblastine; platinum; etoposide (VP-16); ifosfamide; mitomycin C; mitoxantrone; vincristine; vinorelbine; navelbine; novantrone; teniposide; daunomycin; aminopterin; xeloda; ibandronate; CPT-11; topoisomerase inhibitor RFS 2000; difluoromethylornithine (DMFO); retinoic acid; esperamicins; capecitabine; and pharmaceutically acceptable salts, acids or derivatives of any of the above. Also included in this definition are anti-hormonal agents that act to regulate or inhibit hormone action on tumors such as anti-estrogens including for example tamoxifen, raloxifene, aromatase inhibiting 4(5)-imidazoles, 4-hydroxytamoxifen, trioxifene, keoxifene, LY117018, onapristone, and toremifene (Fareston); and anti-androgens such as flutamide, nilutamide, bicalutamide, leuprolide, and goserelin; and pharmaceutically acceptable salts, acids or derivatives of any of the above.
[0078] “Mammal” for purposes of treatment refers to any animal classified as a mammal, including humans, mice, SCID or nude mice or strains of mice, domestic and farm animals, and zoo, sports, or pet animals, such as sheep, dogs, horses, cats, cows, etc. Preferably, the mammal herein is human.
[0079] “Oligonucleotides” are short-length, single- or double-stranded polydeoxynucleotides that are chemically synthesized by known methods (such as phosphotriester, phosphite, or phosphoramidite chemistry, using solid phase techniques such as described in EP 266,032, published 4 May 1988, or via deoxynucleoside H-phosphonate intermediates as described by Froehler et al., Nucl. Acids Res., 14:5399-5407, 1986. They are then purified on polyacrylamide gels.
[0080] In accordance with the present invention, “humanized” and/or “chimeric” forms of non-human (e.g. murine) immunoglobulins refer to antibodies which contain specific chimeric immunoglobulins, immunoglobulin chains or fragments thereof (such as Fv, Fab, Fab′, F(ab′) 2 or other antigen-binding subsequences of antibodies) which results in the decrease of a human anti-mouse antibody (HAMA), human anti-chimeric antibody (HACA) or a human anti-human antibody (HAHA) response, compared to the original antibody, and contain the requisite portions (e.g. CDR(s), antigen binding region(s), variable domain(s) and so on) derived from said non-human immunoglobulin, necessary to reproduce the desired effect, while simultaneously retaining binding characteristics which are comparable to said non-human immunoglobulin. For the most part, humanized antibodies are human immunoglobulins (recipient antibody) in which residues from the complementarity determining regions (CDRs) of the recipient antibody are replaced by residues from the CDRs of a non-human species (donor antibody) such as mouse, rat or rabbit having the desired specificity, affinity and capacity. In some instances, Fv framework region (FR) residues of the human immunoglobulin are replaced by corresponding non-human FR residues. Furthermore, the humanized antibody may comprise residues which are found neither in the recipient antibody nor in the imported CDR or FR sequences. These modifications are made to further refine and optimize antibody performance. In general, the humanized antibody will comprise substantially all of at least one, and typically two, variable domains, in which all or substantially all of the CDR regions correspond to those of a non-human immunoglobulin and all or substantially all of the FR residues are those of a human immunoglobulin consensus sequence. The humanized antibody optimally also will comprise at least a portion of an immunoglobulin constant region (Fc), typically that of a human immunoglobulin.
[0081] “De-immunized” antibodies are immunoglobulins that are non-immunogenic, or less immunogenic, to a given species. De-immunization can be achieved through structural alterations to the antibody. Any de-immunization technique known to those skilled in the art can be employed. One suitable technique for de-immunizing antibodies is described, for example, in WO 00/34317 published Jun. 15, 2000.
[0082] An antibody which induces “apoptosis” is one which induces programmed cell death by any means, illustrated by but not limited to binding of annexin V, caspase activity, fragmentation of DNA, cell shrinkage, dilation of endoplasmic reticulum, cell fragmentation, and/or formation of membrane vesicles (called apoptotic bodies).
[0083] As used herein “antibody induced cytotoxicity” is understood to mean the cytotoxic effect derived from the hybridoma supernatant or antibody produced by the hybridoma deposited with the IDAC as accession number 051206-04 which effect is not necessarily related to the degree of binding.
[0084] Throughout the instant specification, hybridoma cell lines, as well as the isolated monoclonal antibodies which are produced therefrom, are alternatively referred to by their internal designation, AR91A9.2 or Depository Designation, IDAC 051206-04.
[0085] As used herein “antibody-ligand” includes a moiety which exhibits binding specificity for at least one epitope of the target antigen, and which may be an intact antibody molecule, antibody fragments, and any molecule having at least an antigen-binding region or portion thereof (i.e., the variable portion of an antibody molecule), e.g., an Fv molecule, Fab molecule, Fab′ molecule, F(ab′).sub.2 molecule, a bispecific antibody, a fusion protein, or any genetically engineered molecule which specifically recognizes and binds at least one epitope of the antigen bound by the isolated monoclonal antibody produced by the hybridoma cell line designated as IDAC 051206-04 (the IDAC 051206-04 antigen).
[0086] As used herein “cancerous disease modifying antibodies” (CDMAB) refers to monoclonal antibodies which modify the cancerous disease process in a manner which is beneficial to the patient, for example by reducing tumor burden or prolonging survival of tumor bearing individuals, and antibody-ligands thereof.
[0087] A “CDMAB related binding agent”, in its broadest sense, is understood to include, but is not limited to, any form of human or non-human antibodies, antibody fragments, antibody ligands, or the like, which competitively bind to at least one CDMAB target epitope.
[0088] A “competitive binder” is understood to include any form of human or non-human antibodies, antibody fragments, antibody ligands, or the like which has binding affinity for at least one CDMAB target epitope
[0089] Tumors to be treated include primary tumors and metastatic tumors, as well as refractory tumors. Refractory tumors include tumors that fail to respond or are resistant to treatment with chemotherapeutic agents alone, antibodies alone, radiation alone or combinations thereof. Refractory tumors also encompass tumors that appear to be inhibited by treatment with such agents but recur up to five years, sometimes up to ten years or longer after treatment is discontinued.
[0090] Tumors that can be treated include tumors that are not vascularized, or not yet substantially vascularized, as well as vascularized tumors. Examples of solid tumors, which can be accordingly treated, include breast carcinoma, lung carcinoma, colorectal carcinoma, pancreatic carcinoma, glioma and lymphoma. Some examples of such tumors include epidermoid tumors, squamous tumors, such as head and neck tumors, colorectal tumors, prostate tumors, breast tumors, lung tumors, including small cell and non-small cell lung tumors, pancreatic tumors, thyroid tumors, ovarian tumors, and liver tumors. Other examples include Kaposi's sarcoma, CNS neoplasms, neuroblastomas, capillary hemangioblastomas, meningiomas and cerebral metastases, melanoma, gastrointestinal and renal carcinomas and sarcomas, rhabdomyosarcoma, glioblastoma, preferably glioblastoma multiforme, and leiomyosarcoma.
[0091] As used herein “antigen-binding region” means a portion of the molecule which recognizes the target antigen.
[0092] As used herein “competitively inhibits” means being able to recognize and bind a determinant site to which the monoclonal antibody produced by the hybridoma cell line designated as IDAC 051206-04, (the IDAC 051206-04 antibody) is directed using conventional reciprocal antibody competition assays. (Belanger L., Sylvestre C. and Dufour D. (1973), Enzyme linked immunoassay for alpha fetoprotein by competitive and sandwich procedures. Clinica Chimica Acta 48, 15).
[0093] As used herein “target antigen” is the IDAC 051206-04 antigen or portions thereof.
[0094] As used herein, an “immunoconjugate” means any molecule or CDMAB such as an antibody chemically or biologically linked to cytotoxins, radioactive agents, cytokines, interferons, target or reporter moieties, enzymes, toxins, anti-tumor drugs or therapeutic agents. The antibody or CDMAB may be linked to the cytotoxin, radioactive agent, cytokine, interferon, target or reporter moiety, enzyme, toxin, anti-tumor drug or therapeutic agent at any location along the molecule so long as it is able to bind its target. Examples of immunoconjugates include antibody toxin chemical conjugates and antibody-toxin fusion proteins.
[0095] Radioactive agents suitable for use as anti-tumor agents are known to those skilled in the art. For example, 131I or 211At is used. These isotopes are attached to the antibody using conventional techniques (e.g. Pedley et al., Br. J. Cancer 68, 69-73 (1993)). Alternatively, the anti-tumor agent which is attached to the antibody is an enzyme which activates a prodrug. A prodrug may be administered which will remain in its inactive form until it reaches the tumor site where it is converted to its cytotoxin form once the antibody complex is administered. In practice, the antibody-enzyme conjugate is administered to the patient and allowed to localize in the region of the tissue to be treated. The prodrug is then administered to the patient so that conversion to the cytotoxic drug occurs in the region of the tissue to be treated. Alternatively, the anti-tumor agent conjugated to the antibody is a cytokine such as interleukin-2 (IL-2), interleukin-4 (IL-4) or tumor necrosis factor alpha (TNF-α). The antibody targets the cytokine to the tumor so that the cytokine mediates damage to or destruction of the tumor without affecting other tissues. The cytokine is fused to the antibody at the DNA level using conventional recombinant DNA techniques. Interferons may also be used.
[0096] As used herein, a “fusion protein” means any chimeric protein wherein an antigen binding region is connected to a biologically active molecule, e.g., toxin, enzyme, fluorescent proteins, luminescent marker, polypeptide tag, cytokine, interferon, target or reporter moiety or protein drug.
[0097] The invention further contemplates CDMAB of the present invention to which target or reporter moieties are linked. Target moieties are first members of binding pairs. Anti-tumor agents, for example, are conjugated to second members of such pairs and are thereby directed to the site where the antigen-binding protein is bound. A common example of such a binding pair is avidin and biotin. In a preferred embodiment, biotin is conjugated to the target antigen of the CDMAB of the present invention, and thereby provides a target for an anti-tumor agent or other moiety which is conjugated to avidin or streptavidin. Alternatively, biotin or another such moiety is linked to the target antigen of the CDMAB of the present invention and used as a reporter, for example in a diagnostic system where a detectable signal-producing agent is conjugated to avidin or streptavidin.
[0098] Detectable signal-producing agents are useful in vivo and in vitro for diagnostic purposes. The signal producing agent produces a measurable signal which is detectable by external means, usually the measurement of electromagnetic radiation. For the most part, the signal producing agent is an enzyme or chromophore, or emits light by fluorescence, phosphorescence or chemiluminescence. Chromophores include dyes which absorb light in the ultraviolet or visible region, and can be substrates or degradation products of enzyme catalyzed reactions.
[0099] Moreover, included within the scope of the present invention is use of the present CDMAB in vivo and in vitro for investigative or diagnostic methods, which are well known in the art. In order to carry out the diagnostic methods as contemplated herein, the instant invention may further include kits, which contain CDMAB of the present invention. Such kits will be useful for identification of individuals at risk for certain type of cancers by detecting over-expression of the CDMAB's target antigen on cells of such individuals.
Diagnostic Assay Kits
[0100] It is contemplated to utilize the CDMAB of the present invention in the form of a diagnostic assay kit for determining the presence of a tumor. The tumor will generally be detected in a patient based on the presence of one or more tumor-specific antigens, e.g. proteins and/or polynucleotides which encode such proteins in a biological sample, such as blood, sera, urine and/or tumor biopsies, which samples will have been obtained from the patient.
[0101] The proteins function as markers which indicate the presence or absence of a particular tumor, for example a colon, breast, lung or prostate tumor. It is further contemplated that the antigen will have utility for the detection of other cancerous tumors. Inclusion in the diagnostic assay kits of binding agents comprised of CDMABs of the present invention, or CDMAB related binding agents, enables detection of the level of antigen that binds to the agent in the biological sample. Polynucleotide primers and probes may be used to detect the level of mRNA encoding a tumor protein, which is also indicative of the presence or absence of a cancer. In order for the binding assay to be diagnostic, data will have been generated which correlates statistically significant levels of antigen, in relation to that present in normal tissue, so as to render the recognition of binding definitively diagnostic for the presence of a cancerous tumor. It is contemplated that a plurality of formats will be useful for the diagnostic assay of the present invention, as are known to those of ordinary skill in the art, for using a binding agent to detect polypeptide markers in a sample. For example, as illustrated in Harlow and Lane, Antibodies: A Laboratory Manual, Cold Spring Harbor Laboratory, Chapters 9-14, 1988. Further contemplated are any and all combinations, permutations or modifications of the afore-described diagnostic assay formats.
[0102] The presence or absence of a cancer in a patient will typically be determined by (a) contacting a biological sample obtained from a patient with a binding agent; (b) detecting in the sample a level of polypeptide that binds to the binding agent; and (c) comparing the level of polypeptide with a predetermined cut-off value.
[0103] In an illustrative embodiment, it is contemplated that the assay will involve the use of a CDMAB based binding agent immobilized on a solid support to bind to and remove the polypeptide from the remainder of the sample. The bound polypeptide may then be detected using a detection reagent that contains a reporter group and specifically binds to the binding agent/polypeptide complex. Illustrative detection reagents may include a CDMAB based binding agent that specifically binds to the polypeptide or an antibody or other agent that specifically binds to the binding agent, such as an anti-immunoglobulin, protein G, protein A or a lectin. In an alternative embodiment, it is contemplated that a competitive assay may be utilized, in which a polypeptide is labeled with a reporter group and allowed to bind to the immobilized binding agent after incubation of the binding agent with the sample. Indicative of the reactivity of the sample with the immobilized binding agent, is the extent to which components of the sample inhibit the binding of the labeled polypeptide to the binding agent. Suitable polypeptides for use within such assays include full length tumor-specific proteins and/or portions thereof, to which the binding agent has binding affinity.
[0104] The diagnostic kit will be provided with a solid support which may be in the form of any material known to those of ordinary skill in the art to which the protein may be attached. Suitable examples may include a test well in a microtiter plate or a nitrocellulose or other suitable membrane. Alternatively, the support may be a bead or disc, such as glass, fiberglass, latex or a plastic material such as polystyrene or polyvinylchloride. The support may also be a magnetic particle or a fiber optic sensor, such as those disclosed, for example, in U.S. Pat. No. 5,359,681.
[0105] It is contemplated that the binding agent will be immobilized on the solid support using a variety of techniques known to those of skill in the art, which are amply described in the patent and scientific literature. The term “immobilization” refers to both noncovalent association, such as adsorption, and covalent attachment, which, in the context of the present invention, may be a direct linkage between the agent and functional groups on the support, or may be a linkage by way of a cross-linking agent. In a preferred, albeit non-limiting embodiment, immobilization by adsorption to a well in a microtiter plate or to a membrane is preferable. Adsorption may be achieved by contacting the binding agent, in a suitable buffer, with the solid support for a suitable amount of time. The contact time may vary with temperature, and will generally be within a range of between about 1 hour and about 1 day.
[0106] Covalent attachment of binding agent to a solid support would ordinarily be accomplished by first reacting the support with a bifunctional reagent that will react with both the support and a functional group, such as a hydroxyl or amino group, on the binding agent. For example, the binding agent may be covalently attached to supports having an appropriate polymer coating using benzoquinone or by condensation of an aldehyde group on the support with an amine and an active hydrogen on the binding partner.
[0107] It is further contemplated that the diagnostic assay kit will take the form of a two-antibody sandwich assay. This assay may be performed by first contacting an antibody, e.g. the instantly disclosed CDMAB that has been immobilized on a solid support, commonly the well of a microtiter plate, with the sample, such that polypeptides within the sample are allowed to bind to the immobilized antibody. Unbound sample is then removed from the immobilized polypeptide-antibody complexes and a detection reagent (preferably a second antibody capable of binding to a different site on the polypeptide) containing a reporter group is added. The amount of detection reagent that remains bound to the solid support is then determined using a method appropriate for the specific reporter group.
[0108] In a specific embodiment, it is contemplated that once the antibody is immobilized on the support as described above, the remaining protein binding sites on the support will be blocked, via the use of any suitable blocking agent known to those of ordinary skill in the art, such as bovine serum albumin or Tween 20™ (Sigma Chemical Co., St. Louis, Mo.). The immobilized antibody would then be incubated with the sample, and polypeptide would be allowed to bind to the antibody. The sample could be diluted with a suitable diluent, such as phosphate-buffered saline (PBS) prior to incubation. In general, an appropriate contact time (i.e., incubation time) would be selected to correspond to a period of time sufficient to detect the presence of polypeptide within a sample obtained from an individual with the specifically selected tumor. Preferably, the contact time is sufficient to achieve a level of binding that is at least about 95 percent of that achieved at equilibrium between bound and unbound polypeptide. Those of ordinary skill in the art will recognize that the time necessary to achieve equilibrium may be readily determined by assaying the level of binding that occurs over a period of time.
[0109] It is further contemplated that unbound sample would then be removed by washing the solid support with an appropriate buffer. The second antibody, which contains a reporter group, would then be added to the solid support. Incubation of the detection reagent with the immobilized antibody-polypeptide complex would then be carried out for an amount of time sufficient to detect the bound polypeptide. Subsequently, unbound detection reagent would then be removed and bound detection reagent would be detected using the reporter group. The method employed for detecting the reporter group is necessarily specific to the type of reporter group selected, for example for radioactive groups, scintillation counting or autoradiographic methods are generally appropriate. Spectroscopic methods may be used to detect dyes, luminescent groups and fluorescent groups. Biotin may be detected using avidin, coupled to a different reporter group (commonly a radioactive or fluorescent group or an enzyme). Enzyme reporter groups may generally be detected by the addition of substrate (generally for a specific period of time), followed by spectroscopic or other analysis of the reaction products.
[0110] In order to utilize the diagnostic assay kit of the present invention to determine the presence or absence of a cancer, such as prostate cancer, the signal detected from the reporter group that remains bound to the solid support would generally be compared to a signal that corresponds to a predetermined cut-off value. For example, an illustrative cut-off value for the detection of a cancer may be the average mean signal obtained when the immobilized antibody is incubated with samples from patients without the cancer. In general, a sample generating a signal that is about three standard deviations above the predetermined cut-off value would be considered positive for the cancer. In an alternate embodiment, the cut-off value might be determined by using a Receiver Operator Curve, according to the method of Sackett et al., Clinical Epidemiology. A Basic Science for Clinical Medicine, Little Brown and Co., 1985, p. 106-7. In such an embodiment, the cut-off value could be determined from a plot of pairs of true positive rates (i.e., sensitivity) and false positive rates (100 percent-specificity) that correspond to each possible cut-off value for the diagnostic test result. The cut-off value on the plot that is the closest to the upper left-hand corner (i.e., the value that encloses the largest area) is the most accurate cut-off value, and a sample generating a signal that is higher than the cut-off value determined by this method may be considered positive. Alternatively, the cut-off value may be shifted to the left along the plot, to minimize the false positive rate, or to the right, to minimize the false negative rate. In general, a sample generating a signal that is higher than the cut-off value determined by this method is considered positive for a cancer.
[0111] It is contemplated that the diagnostic assay enabled by the kit will be performed in either a flow-through or strip test format, wherein the binding agent is immobilized on a membrane, such as nitrocellulose. In the flow-through test, polypeptides within the sample bind to the immobilized binding agent as the sample passes through the membrane. A second, labeled binding agent then binds to the binding agent-polypeptide complex as a solution containing the second binding agent flows through the membrane. The detection of bound second binding agent may then be performed as described above. In the strip test format, one end of the membrane to which binding agent is bound will be immersed in a solution containing the sample. The sample migrates along the membrane through a region containing second binding agent and to the area of immobilized binding agent. Concentration of the second binding agent at the area of immobilized antibody indicates the presence of a cancer. Generation of a pattern, such as a line, at the binding site, which can be read visually, will be indicative of a positive test. The absence of such a pattern indicates a negative result. In general, the amount of binding agent immobilized on the membrane is selected to generate a visually discernible pattern when the biological sample contains a level of polypeptide that would be sufficient to generate a positive signal in the two-antibody sandwich assay, in the format discussed above. Preferred binding agents for use in the instant diagnostic assay are the instantly disclosed antibodies, antigen-binding fragments thereof, and any CDMAB related binding agents as herein described. The amount of antibody immobilized on the membrane will be any amount effective to produce a diagnostic assay, and may range from about 25 nanograms to about 1 microgram. Typically such tests may be performed with a very small amount of biological sample.
[0112] Additionally, the CDMAB of the present invention may be used in the laboratory for research due to its ability to identify its target antigen.
[0113] In order that the invention herein described may be more fully understood, the following description is set forth.
[0114] The present invention provides CDMAB (i.e., IDAC 051206-04 CDMAB) which specifically recognize and bind the IDAC 051206-04 antigen.
[0115] The CDMAB of the isolated monoclonal antibody produced by the hybridoma deposited with the IDAC as accession number 051206-04 may be in any form as long as it has an antigen-binding region which competitively inhibits the immunospecific binding of the isolated monoclonal antibody produced by hybridoma IDAC 051206-04 to its target antigen. Thus, any recombinant proteins (e.g., fusion proteins wherein the antibody is combined with a second protein such as a lymphokine or a tumor inhibitory growth factor) having the same binding specificity as the IDAC 051206-04 antibody fall within the scope of this invention.
[0116] In one embodiment of the invention, the CDMAB is the IDAC 051206-04 antibody.
[0117] In other embodiments, the CDMAB is an antigen binding fragment which may be a Fv molecule (such as a single-chain Fv molecule), a Fab molecule, a Fab′ molecule, a F(ab′)2 molecule, a fusion protein, a bispecific antibody, a heteroantibody or any recombinant molecule having the antigen-binding region of the IDAC 051206-04 antibody. The CDMAB of the invention is directed to the epitope to which the IDAC 051206-04 monoclonal antibody is directed.
[0118] The CDMAB of the invention may be modified, i.e., by amino acid modifications within the molecule, so as to produce derivative molecules. Chemical modification may also be possible. Modification by direct mutation, methods of affinity maturation, phage display or chain shuffling may also be possible.
[0119] Affinity and specificity can be modified or improved by mutating CDR and/or phenylalanine tryptophan (FW) residues and screening for antigen binding sites having the desired characteristics (e.g., Yang et al., J. Mol. Biol., (1995) 254: 392-403). One way is to randomize individual residues or combinations of residues so that in a population of otherwise identical antigen binding sites, subsets of from two to twenty amino acids are found at particular positions. Alternatively, mutations can be induced over a range of residues by error prone PCR methods (e.g., Hawkins et al., J. Mol. Biol., (1992) 226: 889-96). In another example, phage display vectors containing heavy and light chain variable region genes can be propagated in mutator strains of E. coli (e.g., Low et al., J. Mol. Biol., (1996) 250: 359-68). These methods of mutagenesis are illustrative of the many methods known to one of skill in the art.
[0120] Another manner for increasing affinity of the antibodies of the present invention is to carry out chain shuffling, where the heavy or light chain are randomly paired with other heavy or light chains to prepare an antibody with higher affinity. The various CDRs of the antibodies may also be shuffled with the corresponding CDRs in other antibodies.
[0121] Derivative molecules would retain the functional property of the polypeptide, namely, the molecule having such substitutions will still permit the binding of the polypeptide to the IDAC 051206-04 antigen or portions thereof.
[0122] These amino acid substitutions include, but are not necessarily limited to, amino acid substitutions known in the art as “conservative”.
[0123] For example, it is a well-established principle of protein chemistry that certain amino acid substitutions, entitled “conservative amino acid substitutions,” can frequently be made in a protein without altering either the conformation or the function of the protein.
[0124] Such changes include substituting any of isoleucine (I), valine (V), and leucine (L) for any other of these hydrophobic amino acids; aspartic acid (D) for glutamic acid (E) and vice versa; glutamine (Q) for asparagine (N) and vice versa; and serine (S) for threonine (T) and vice versa. Other substitutions can also be considered conservative, depending on the environment of the particular amino acid and its role in the three-dimensional structure of the protein. For example, glycine (G) and alanine (A) can frequently be interchangeable, as can alanine and valine (V). Methionine (M), which is relatively hydrophobic, can frequently be interchanged with leucine and isoleucine, and sometimes with valine. Lysine (K) and arginine (R) are frequently interchangeable in locations in which the significant feature of the amino acid residue is its charge and the differing pK's of these two amino acid residues are not significant. Still other changes can be considered “conservative” in particular environments.
EXAMPLE 1
Hybridoma Production—Hybridoma Cell Line AR91A9.2
[0125] The hybridoma cell line AR91A9.2 was deposited, in accordance with the Budapest Treaty, with the International Depository Authority of Canada (IDAC), Bureau of Microbiology, Health Canada, 1015 Arlington Street, Winnipeg, Manitoba, Canada, R3E,3R2, on Dec. 5, 2006, under Accession Number 051206-04. In accordance with 37 CFR 1.808, the depositors assure that all restrictions imposed on the availability to the public of the deposited materials will be irrevocably removed upon the granting of a patent. The deposit will be replaced if the depository cannot dispense viable samples.
[0126] To produce the hybridoma that produces the anti-cancer antibody AR91A9.2, a single cell suspension of frozen lung adenocarcinoma tumor tissue (Genomics Collaborative, Cambridge, Mass.) was prepared in PBS. IMMUNEASY™ (Qiagen, Venlo, Netherlands) adjuvant was prepared for use by gentle mixing. Five to seven week old BALB/c mice were immunized by injecting subcutaneously 2 million cells in 50 microliters of the antigen-adjuvant. Recently prepared antigen-adjuvant was used to boost the immunized mice intraperitoneally, 2 and 5 weeks after the initial immunization, with 2 million cells in 50 microliters. A spleen was used for fusion three days after the last immunization. The hybridomas were prepared by fusing the isolated splenocytes with NSO-1 myeloma partners. The supernatants from the fusions were tested from subclones of the hybridomas.
[0127] To determine whether the antibodies secreted by the hybridoma cells are of the IgG or IgM isotype, an ELISA assay was employed. 100 microliters/well of goat anti-mouse IgG+IgM (H+L) at a concentration of 2.4 micrograms/mL in coating buffer (0.1 M carbonate/bicarbonate buffer, pH 9.2-9.6) at 4° C. was added to the ELISA plates overnight. The plates were washed thrice in washing buffer (PBS+0.05 percent Tween). 100 microliters/well blocking buffer (5 percent milk in wash buffer) was added to the plate for 1 hour at room temperature and then washed thrice in washing buffer. 100 microliters/well of hybridoma supernatant was added and the plate incubated for 1 hour at room temperature. The plates were washed thrice with washing buffer and 1/100,000 dilution of either goat anti-mouse IgG or IgM horseradish peroxidase conjugate (diluted in PBS containing 1 percent milk), 100 microliters/well, was added. After incubating the plate for 1 hour at room temperature the plate was washed thrice with washing buffer. 100 microliters/well of TMB solution was incubated for 1-3 minutes at room temperature. The color reaction was terminated by adding 50 microliters/well 2M H 2 S0 4 and the plate was read at 450 nm with a Perkin-Elmer HTS7000 plate reader. As indicated in FIG. 1 , the AR91A9.2 hybridoma secreted primarily antibodies of the IgG isotype.
[0128] To determine the subclass of antibody secreted by the hybridoma cells, an isotyping experiment was performed using a Mouse Monoclonal Antibody Isotyping Kit (HyCult Biotechnology, Frontstraat, Netherlands). 500 microliters of buffer solution was added to the test strip containing rat anti-mouse subclass specific antibodies. 500 microliters of hybridoma supernatant was added to the test tube, and submerged by gentle agitation. Captured mouse immunoglobulins were detected directly by a second rat monoclonal antibody which is coupled to colloid particles. The combination of these two proteins creates a visual signal used to analyze the isotype. The anti-cancer antibody AR91A9.2 is of the IgG2a, kappa isotype.
[0129] After one round of limiting dilution, hybridoma supernatants were tested for antibodies that bound to target cells in a cell ELISA assay. Three human lung cancer cell lines, 1 human breast cancer cell lines and 1 human non-cancer lung cell line were tested: A549, NCI-H23, NCI-H460, MDA-MB-231 and Hs888.Lu respectively. All cell lines were obtained from the American Type Tissue Collection (ATCC, Manassas, Va.). The plated cells were fixed prior to use. The plates were washed thrice with PBS containing MgCl 2 and CaCl 2 at room temperature. 100 microliters of 2 percent paraformaldehyde diluted in PBS was added to each well for 10 minutes at room temperature and then discarded. The plates were again washed with PBS containing MgCl 2 and CaCl 2 three times at room temperature. Blocking was done with 100 microliters/well of 5 percent milk in wash buffer (PBS+0.05 percent Tween) for 1 hour at room temperature. The plates were washed thrice with wash buffer and the hybridoma supernatant was added at 100 microliters/well for 1 hour at room temperature. The plates were washed 3 times with wash buffer and 100 microliters/well of 1/25,000 dilution of goat anti-mouse IgG antibody conjugated to horseradish peroxidase (diluted in PBS containing 1 percent milk) was added. After 1 hour incubation at room temperature the plates were washed 3 times with wash buffer and 100 microliter/well of TMB substrate was incubated for 1-3 minutes at room temperature. The reaction was terminated with 50 microliters/well 2M H 2 S0 4 and the plate read at 450 nm with a Perkin-Elmer HTS7000 plate reader. The results as tabulated in FIG. 1 were expressed as the number of folds above background compared to an in-house IgG isotype control that has previously been shown not to bind to the cell lines tested. The antibodies from the hybridoma AR91A9.2 showed strong binding to the A549, NCI-H23, NCI-H460 lung cancer cell lines and the MDA-MB-231 breast cancer cell line with no detectable binding to the non-cancer lung cell line Hs888.Lu.
[0130] In conjunction with testing for antibody binding, the cytotoxic effect of the hybridoma supernatants (antibody induced cytotoxicity) was tested in the cell lines: A549, NCI-H23, NCI-H460, MDA-MB-231 and Hs888.Lu. Calcein AM was obtained from Molecular Probes (Eugene, Oreg.) and the assay was performed as outlined below. Cells were plated before the assay at the predetermined appropriate density. After 2 days, 100 microliters of supernatant from the hybridoma microtitre plates were transferred to the cell plates and incubated in a 5 percent CO 2 incubator for 5 days. The wells that served as the positive controls were aspirated until empty and 100 microliters of sodium azide (NaN 3 , 0.01 percent, Sigma, Oakville, ON) or cycloheximide (CHX, 0.5 micromolar, Sigma, Oakville, ON) dissolved in culture medium, was added. After 5 days of treatment, the plates were then emptied by inverting and blotting dry. Room temperature DPBS (Dulbecco's phosphate buffered saline) containing MgCl 2 and CaCl 2 was dispensed into each well from a multichannel squeeze bottle, tapped 3 times, emptied by inversion and then blotted dry. 50 microliters of the fluorescent calcein dye diluted in DPBS containing MgCl 2 and CaCl 2 was added to each well and incubated at 37° C. in a 5 percent CO 2 incubator for 30 minutes. The plates were read in a Perkin-Elmer HTS7000 fluorescence plate reader and the data was analyzed in Microsoft Excel. The results are tabulated in FIG. 1 . Supernatant from the AR91A9.2 hybridoma produced specific cytotoxicity of 31 percent on the NCI-H460 lung cancer cells. This was 43 and 69 percent of the cytotoxicity obtained with the positive controls sodium azide and cycloheximide, respectively.
[0131] Results from FIG. 1 demonstrated that the cytotoxic effects of AR91A9.2 were not directly correlated to the binding levels on the cancer cell types. Although there was similar binding to the lung and breast cancer cell lines, cytotoxicity was only detectable in the NCI-H460 cells. As tabulated in FIG. 1 , AR91A9.2 did not produce cytotoxicity in the Hs888.Lu non-cancer human lung cell line. The known non-specific cytotoxic agents cycloheximide and NaN 3 generally produced cytotoxicity as expected.
EXAMPLE 2
In Vitro Binding
[0132] AR91A9.2 monoclonal antibody was produced by culturing the hybridoma in CL-1000 flasks (BD Biosciences, Oakville, ON) with collections and reseeding occurring twice/week. Standard antibody purification procedures with Protein G Sepharose 4 Fast Flow (Amersham Biosciences, Baie d'Urfé, QC) were followed. It is within the scope of this invention to utilize monoclonal antibodies that are de-immunized, humanized, chimeric or murine.
[0133] Binding of AR91A9.2 to lung (A549, NCI-H23, NCI-H322M, NCI-H460 and NCI-H520), colon (Lovo), breast (MDA-MB-231), pancreatic (BxPC-3), prostate (PC-3) and ovarian (OVCAR-3) cancer, and non-cancer cell lines from skin (CCD-27sk) and lung (Hs888.Lu) was assessed by flow cytometry (FACS). All cell lines, except for the lung cancer cell line NCI-H322M, were obtained from the American Type Tissue Collection (ATCC, Manassas, Va.). NCI-H322M was obtained from the NCI-Frederick Cancer DCTD Tumor/Cell Line Repository (Frederick, Md.).
[0134] Cells were prepared for FACS by initially washing the cell monolayer with DPBS (without Ca ++ and Mg ++ ). Cell dissociation buffer (Invitrogen, Burlington, ON) was then used to dislodge the cells from their cell culture plates at 37° C. After centrifugation and collection, the cells were resuspended in DPBS containing MgCl 2 , CaCl 2 and 2 percent fetal bovine serum at 4° C. (staining media) and counted, aliquoted to appropriate cell density, spun down to pellet the cells and resuspended in staining media at 4° C. in the presence of the test antibody (AR91A9.2) or control antibodies (isotype control, anti-EGFR). Isotype control and the test antibody were assessed at 20 micrograms/mL whereas anti-EGFR was assessed at 5 micrograms/mL on ice for 30 minutes. Prior to the addition of Alexa Fluor 546-conjugated secondary antibody the cells were washed once with staining media. The Alexa Fluor 546-conjugated antibody in staining media was then added for 30 minutes at 4° C. The cells were then washed for the final time and resuspended in fixing media (staining media containing 1.5 percent paraformaldehyde). Flow cytometric acquisition of the cells was assessed by running samples on a FACSarray™ using the FACSarray™ System Software (BD Biosciences, Oakville, ON). The forward (FSC) and side scatter (SSC) of the cells were set by adjusting the voltage and amplitude gains on the FSC and SSC detectors. The detectors for the fluorescence (Alexa-546) channel was adjusted by running unstained cells such that cells had a uniform peak with a median fluorescent intensity of approximately 1-5 units. For each sample, approximately 10,000 gated events (stained fixed cells) were acquired for analysis and the results are presented in FIG. 2 .
[0135] FIG. 2 presents the mean fluorescence intensity fold increase above isotype control. Representative histograms of AR91A9.2 antibodies were compiled for FIG. 3 . AR91A9.2 demonstrated detectable binding to all of the cell lines tested with the strongest binding detected to the lung cancer cell lines A549 (31.1-fold), NCI-H322M (23.7-fold) and NCI-H520 (23.3-fold). Moderate binding was detected to the lung cancer cell lines NCI-H23 (11.4-fold) and NCI-H460 (18.3-fold) and the ovarian cancer cell line OVCAR-3 (10.2-fold). Lower binding was detected on the remaining cancer and non-cancer cell lines. These data demonstrate that AR91A9.2 bound to several different cell lines with varying levels of antigen expression.
EXAMPLE 3
In Vivo Tumor Experiments with NCI-H520 Cells
[0136] Examples 1 and 2 demonstrated that AR91A9.2 had anti-cancer properties against human cancer cell lines with detectable binding across several different cancer indications. With reference to FIGS. 4 and 5 , 8 to 10 week old female SCID mice were implanted with 5 million human lung carcinoma cells (NCI-H520) in 100 microlitres PBS solution injected subcutaneously in the scruff of the neck. The mice were randomly divided into 2 treatment groups of 6. On the day after implantation, 20 mg/kg of AR91A9.2 test antibody or buffer control was administered intraperitoneally to each cohort in a volume of 300 microlitres after dilution from the stock concentration with a diluent that contained 2.7 mM KCl, 1 mM KH 2 PO 4 , 137 mM NaCl and 20 mM Na 2 HPO 4 . The antibody and control samples were then administered once per week for the duration of the study in the same fashion. Tumor growth was measured about every seventh day with calipers. The study was completed after 8 doses of antibody. Body weights of the animals were recorded once per week for the duration of the study. At the end of the study all animals were euthanized according to CCAC guidelines.
[0137] AR91A9.2 reduced tumor growth in the NCI-H520 in vivo prophylactic model of human lung cancer. Treatment with ARIUS antibody AR91A9.2 reduced the growth of NCI-H520 tumors by 51.3 percent compared to the buffer treated group. The result failed to reach significance (p=0.23, t-test) due to the low numbers of mice in each group, but the tumor size in the antibody-treated group was lower at every time point than that of the vehicle control. On day 41, when all mice were still alive, tumor growth was inhibited by 54 percent (p=0.18, t-test) ( FIG. 4 ).
[0138] There were no clinical signs of toxicity throughout the study. Body weight measured at weekly intervals was a surrogate for well-being and failure to thrive. The mean body weight increased in all groups over the duration of the study ( FIG. 5 ). The mean weight gain between day 1 and day 62 was 3.73 g (17.2 percent) in the control group and 1.4 g (6.4 percent) in the AR91A9.2-treated group. There were no significant differences between groups at the end of the treatment period.
[0139] In summary, AR91A9.2 was well-tolerated and decreased the tumor burden in this human lung carcinoma xenograft model.
EXAMPLE 4
Isolation of Competitive Binders
[0140] Given an antibody, an individual ordinarily skilled in the art can generate a competitively inhibiting CDMAB, for example a competing antibody, which is one that recognizes the same epitope (Belanger L et al. Clinica Chimica Acta 48:15-18 (1973)). One method entails immunizing with an immunogen that expresses the antigen recognized by the antibody. The sample may include but is not limited to tissues, isolated protein(s) or cell line(s). Resulting hybridomas could be screened using a competition assay, which is one that identifies antibodies that inhibit the binding of the test antibody, such as ELISA, FACS or Western blotting. Another method could make use of phage display antibody libraries and panning for antibodies that recognize at least one epitope of said antigen (Rubinstein J L et al. Anal Biochem 314:294-300 (2003)). In either case, antibodies are selected based on their ability to displace the binding of the original labeled antibody to at least one epitope of its target antigen. Such antibodies would therefore possess the characteristic of recognizing at least one epitope of the antigen as the original antibody.
EXAMPLE 5
Cloning of the Variable Regions of the AR91A9.2 Monoclonal Antibody
[0141] The sequences of the variable regions from the heavy (V H ) and light (V L ) chains of monoclonal antibody produced by the AR91A9.2 hybridoma cell line can be determined. RNA encoding the heavy and light chains of immunoglobulin can be extracted from the subject hybridoma using standard methods involving cellular solubilization with guanidinium isothiocyanate (Chirgwin et al. Biochem. 18:5294-5299 (1979)). The mRNA can be used to prepare cDNA for subsequent isolation of V H and V L genes by PCR methodology known in the art (Sambrook et al., eds., Molecular Cloning, Chapter 14, Cold Spring Harbor laboratories Press, N.Y. (1989)). The N-terminal amino acid sequence of the heavy and light chains can be independently determined by automated Edman sequencing. Further stretches of the CDRs and flanking FRs can also be determined by amino acid sequencing of the V H and V L fragments. Synthetic primers can be then designed for isolation of the V H and V L genes from AR91A9.2 monoclonal antibody, and the isolated gene can be ligated into an appropriate vector for sequencing. To generate chimeric and humanized IgG, the variable light and variable heavy domains can be subcloned into an appropriate vector for expression.
[0142] In another embodiment, AR91A9.2 or its de-immunized, chimeric or humanized version is produced by expressing a nucleic acid encoding the antibody in a transgenic animal, such that the antibody is expressed and can be recovered. For example, the antibody can be expressed in a tissue specific manner that facilitates recovery and purification. In one such embodiment, an antibody of the invention is expressed in the mammary gland for secretion during lactation. Transgenic animals include but are not limited to mice, goat and rabbit.
[0143] (i) Monoclonal Antibody
[0144] DNA encoding the monoclonal antibody (as outlined in Example 1) is readily isolated and sequenced using conventional procedures (e.g., by using oligonucleotide probes that are capable of binding specifically to genes encoding the heavy and light chains of the monoclonal antibodies). The hybridoma cell serves as a preferred source of such DNA. Once isolated, the DNA may be placed into expression vectors, which are then transfected into host cells such as E. coli cells, simian COS cells, Chinese hamster ovary (CHO) cells, or myeloma cells that do not otherwise produce immunoglobulin protein, to obtain the synthesis of monoclonal antibodies in the recombinant host cells. The DNA also may be modified, for example, by substituting the coding sequence for human heavy and light chain constant domains in place of the homologous murine sequences. Chimeric or hybrid antibodies also may be prepared in vitro using known methods in synthetic protein chemistry, including those involving crosslinking agents. For example, immunotoxins may be constructed using a disulfide exchange reaction or by forming a thioether bond. Examples of suitable reagents for this purpose include iminothiolate and methyl-4-mercaptobutyrimidate.
[0145] (ii) Humanized Antibody
[0146] A humanized antibody has one or more amino acid residues introduced into it from a non-human source. These non-human amino acid residues are often referred to as “import” residues, which are typically taken from an “import” variable domain. Humanization can be performed the method of Winter and co-workers by substituting rodent CDRs or CDR sequences for the corresponding sequences of a human antibody (Jones et al., Nature 321:522-525 (1986); Riechmann et al., Nature 332:323-327 (1988); Verhoeyen et al, Science 239:1534-1536 (1988); reviewed in Clark, Immunol. Today 21:397-402 (2000)).
[0147] A humanized antibody can be prepared by a process of analysis of the parental sequences and various conceptual humanized products using three-dimensional models of the parental and humanized sequences. Three dimensional immunoglobulin models are commonly available and are familiar to those skilled in the art. Computer programs are available which illustrate and display probable three-dimensional conformational structures of selected candidate immunoglobulin sequences. Inspection of these displays permits analysis of the likely role of the residues in the functioning of the candidate immunoglobulin sequence, i.e. the analysis of residues that influence the ability of the candidate immunoglobulin to bind its antigen. In this way, FR residues can be selected and combined from the consensus and import sequence so that the desired antibody characteristic, such as increased affinity for the target antigen(s), is achieved. In general, the CDR residues are directly and most substantially involved in influencing antigen binding.
[0148] (iii) Antibody Fragments
[0149] Various techniques have been developed for the production of antibody fragments. These fragments can be produced by recombinant host cells (reviewed in Hudson, Curr. Opin. Immunol. 11:548-557 (1999); Little et al., Immunol. Today 21:364-370 (2000)). For example, Fab′-SH fragments can be directly recovered from E. coli and chemically coupled to form F(ab′) 2 fragments (Carter et al., Biotechnology 10:163-167 (1992)). In another embodiment, the F(ab′) 2 is formed using the leucine zipper GCN4 to promote assembly of the F(ab′) 2 molecule. According to another approach, Fv, Fab or F(ab′) 2 fragments can be isolated directly from recombinant host cell culture.
EXAMPLE 6
A Composition Comprising the Antibody of the Present Invention
[0150] The antibody of the present invention can be used as a composition for preventing/treating cancer. The composition for preventing/treating cancer, which comprises the antibody of the present invention, are low-toxic and can be administered as they are in the form of liquid preparations, or as pharmaceutical compositions of suitable preparations to human or mammals (e.g., rats, rabbits, sheep, swine, bovine, feline, canine, simian, etc.) orally or parenterally (e.g., intravascularly, intraperitoneally, subcutaneously, etc.). The antibody of the present invention may be administered in itself, or may be administered as an appropriate composition. The composition used for the administration may contain a pharmacologically acceptable carrier with the antibody of the present invention or its salt, a diluent or excipient. Such a composition is provided in the form of pharmaceutical preparations suitable for oral or parenteral administration.
[0151] Examples of the composition for parenteral administration are injectable preparations, suppositories, etc. The injectable preparations may include dosage forms such as intravenous, subcutaneous, intracutaneous and intramuscular injections, drip infusions, intraarticular injections, etc. These injectable preparations may be prepared by methods publicly known. For example, the injectable preparations may be prepared by dissolving, suspending or emulsifying the antibody of the present invention or its salt in a sterile aqueous medium or an oily medium conventionally used for injections. As the aqueous medium for injections, there are, for example, physiological saline, an isotonic solution containing glucose and other auxiliary agents, etc., which may be used in combination with an appropriate solubilizing agent such as an alcohol (e.g., ethanol), a polyalcohol (e.g., propylene glycol, polyethylene glycol), a nonionic surfactant (e.g., polysorbate 80, HCO-50 (polyoxyethylene (50 mols) adduct of hydrogenated castor oil)), etc. As the oily medium, there are employed, e.g., sesame oil, soybean oil, etc., which may be used in combination with a solubilizing agent such as benzyl benzoate, benzyl alcohol, etc. The injection thus prepared is usually filled in an appropriate ampoule. The suppository used for rectal administration may be prepared by blending the antibody of the present invention or its salt with conventional bases for suppositories. The composition for oral administration includes solid or liquid preparations, specifically, tablets (including dragees and film-coated tablets), pills, granules, powdery preparations, capsules (including soft capsules), syrup, emulsions, suspensions, etc. Such a composition is manufactured by publicly known methods and may contain a vehicle, a diluent or excipient conventionally used in the field of pharmaceutical preparations. Examples of the vehicle or excipient for tablets are lactose, starch, sucrose, magnesium stearate, etc.
[0152] Advantageously, the compositions for oral or parenteral use described above are prepared into pharmaceutical preparations with a unit dose suited to fit a dose of the active ingredients. Such unit dose preparations include, for example, tablets, pills, capsules, injections (ampoules), suppositories, etc. The amount of the aforesaid compound contained is generally 5 to 500 mg per dosage unit form; it is preferred that the antibody described above is contained in about 5 to about 100 mg especially in the form of injection, and in 10 to 250 mg for the other forms.
[0153] The dose of the aforesaid prophylactic/therapeutic agent or regulator comprising the antibody of the present invention may vary depending upon subject to be administered, target disease, conditions, route of administration, etc. For example, when used for the purpose of treating/preventing, e.g., breast cancer in an adult, it is advantageous to administer the antibody of the present invention intravenously in a dose of about 0.01 to about 20 mg/kg body weight, preferably about 0.1 to about 10 mg/kg body weight and more preferably about 0.1 to about 5 mg/kg body weight, about 1 to 5 times/day, preferably about 1 to 3 times/day. In other parenteral and oral administration, the agent can be administered in a dose corresponding to the dose given above. When the condition is especially severe, the dose may be increased according to the condition.
[0154] The antibody of the present invention may be administered as it stands or in the form of an appropriate composition. The composition used for the administration may contain a pharmacologically acceptable carrier with the aforesaid antibody or its salts, a diluent or excipient. Such a composition is provided in the form of pharmaceutical preparations suitable for oral or parenteral administration (e.g., intravascular injection, subcutaneous injection, etc.). Each composition described above may further contain other active ingredients. Furthermore, the antibody of the present invention may be used in combination with other drugs, for example, alkylating agents (e.g., cyclophosphamide, ifosfamide, etc.), metabolic antagonists (e.g., methotrexate, 5-fluorouracil, etc.), anti-tumor antibiotics (e.g., mitomycin, adriamycin, etc.), plant-derived anti-tumor agents (e.g., vincristine, vindesine, Taxol, etc.), cisplatin, carboplatin, etoposide, irinotecan, etc. The antibody of the present invention and the drugs described above may be administered simultaneously or at staggered times to the patient.
[0155] The method of treatment described herein, particularly for cancers, may also be carried out with administration of other antibodies or chemotherapeutic agents. For example, an antibody against EGFR, such as ERBITUX® (cetuximab), may also be administered, particularly when treating colon cancer. ERBITUX® has also been shown to be effective for treatment of psoriasis. Other antibodies for combination use include Herceptin® (trastuzumab) particularly when treating breast cancer, AVASTIN® particularly when treating colon cancer and SGN-15 particularly when treating non-small cell lung cancer. The administration of the antibody of the present invention with other antibodies/chemotherapeutic agents may occur simultaneously, or separately, via the same or different route.
[0156] The chemotherapeutic agent/other antibody regimens utilized include any regimen believed to be optimally suitable for the treatment of the patient's condition. Different malignancies can require use of specific anti-tumor antibodies and specific chemotherapeutic agents, which will be determined on a patient to patient basis. In a preferred embodiment of the invention, chemotherapy is administered concurrently with or, more preferably, subsequent to antibody therapy. It should be emphasized, however, that the present invention is not limited to any particular method or route of administration.
[0157] The preponderance of evidence shows that AR91A9.2 mediates anti-cancer effects through ligation of an epitope present on cancer cell lines. Further it could be shown that the AR91A9.2 antibody could be used in detection of cells which express the epitope which specifically binds thereto; utilizing techniques illustrated by, but not limited to FACS, cell ELISA or IHC.
[0158] 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.
[0159] 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 of parts 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.
[0160] One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. Any oligonucleotides, peptides, polypeptides, biologically related compounds, 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.
|
The present invention relates to a method for producing cancerous disease modifying antibodies using a novel paradigm of screening. By segregating the anti-cancer antibodies using cancer cell cytotoxicity as an end point, the process makes possible the production of anti-cancer antibodies for therapeutic and diagnostic purposes. The antibodies can be used in aid of staging and diagnosis of a cancer, and can be used to treat primary tumors and tumor metastases. The anti-cancer antibodies can be conjugated to toxins, enzymes, radioactive compounds, cytokines, interferons, target or reporter moieties and hematogenous cells.
| 6
|
RELATED APPLICATION
[0001] This application claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Patent Application Ser. No. 61/716,729 filed Oct. 22, 2012, which is incorporated herein by reference in its entirety and made a part hereof.
FIELD OF INVENTION
[0002] The present invention relates to Mobile Digital Video Recorder (MDVR) and Dual Stage Hybrid Drive (DHD) type of MDVR.
BACKGROUND OF THE INVENTION
[0003] Mobile Digital Video Recorder (MDVR) is a recording device installed on vehicle, vessels or airplane that records the digital information onto a Data Storage Device (DSD). Digital information includes digital format of video and audio signals, GPS data, temperature, vehicle speed, and other vehicle data. The MDVR may have an analog to digital convertor to convert the video and audio analog signals from analog cameras and microphones to digital format. The MDVR may have one or more network interface to connect to IP cameras, which provide the digital format of the video and audio signal.
[0004] MDVRs that use a Hard Disk Drive (HDD) as a digital storage device have to turn on power to the HDD during the recording. If the MDVR is recording for 18 hours out of 24 hours a day, the HDD has to be powered on for at least 18 hours out of 24 hours. With the HDD running for that period of time per day, the ambient temperature of the HDD can be over 60° C. from heating or less than −10° C. from environmental conditions, additionally the HDD can be subjected to excessive shock and vibration. All of these factors can significantly reduce the service life of the HDD.
[0005] On the other hand, an MDVR that uses Flash Memory Card (FMC) for DSD is more robust but has less storage space for the same cost as MDVR using HDD for DSD. The HDD has large storage space but it contains moving parts and has limited operating conditions. The HDD may not be used when the operating temperature is less than −5° C., in addition, the HDD may not be used when the operating temperature is greater than 60° C. The HDD's reliability is dramatically reduced when it is operating in an environment with temperatures higher than 50° C. and in an environment where it is constantly subjected to shock and vibration. Operating the HDD in an excessive shock or vibration environment will reduce its service life and will cause permanent damage to the HDD and a loss of data.
[0006] The prior art discloses attempts at protecting the HDD from vibration and shock. U.S. Pat. No. 7,768,548 describe a ruggedized multiple video and audio input system to be placed in vehicles. However, the described device does not describe any sensors for temperature, shock or otherwise for monitoring the state of the recordable drive. Additionally, the devices solely relies on a HDD which in case of failure would lead the device unable to store recorded data.
[0007] Avoiding storage devices with moving parts in order to increase reliability has been attempted in the prior art. U.S. application Ser. No. 10/691,483 discloses an in-car video system that uses flash memory for storage. While flash memory cards are reliable and do not posses any moving parts, they do have limited write cycles requiring eventual replacement. As well, the storage capacity of flash memory is severely limited compared to HDDs.
[0008] EP Application No. 2064706 A1 filed by Bisson and Oullette describes a mobile event recorder containing a vibration isolation system surrounding hard drive housing and enclosed within a hard drive module chassis. This device only isolates the HDD(s) from ambient vibrations and does not contain system for removing power from the HDD during excessive vibration outside of the defined vibrational range of this device, as well as in low or high temperatures as in the present invention. It also does not describe multiple storage devices such as an FMC or SSD.
[0009] U.S. Pat. No. 5,860,083 issued to Hiroshi Sukegawa discloses a data storage system using a flash memory unit and an HDD. The flash memory is dived into a permanent storage area, a non-volatile cache area and a high-speed access area. This device is designed to use the cooperative functions of the flash memory and HDD and allow for efficient use of the data storage system. The described system does not use regulate the function of the HDD based on environmental sensor and does not transfer data during defined times and operating ranges as the present invention. It also does not contain inputs for the storage of video, audio and sensor data as the present invention.
SUMMARY OF THE INVENTION
[0010] The present Removable Dual Stage Hybrid Drive (RDHD) is a digital storage device comprising of a metal or plastic enclosure that houses one or more Hard Disk Drives, one or more Flash Memory Cards or Solid State Drives (SSDs), one or more connectors to the MDVR, which provide the USB interface signals, SATA signals, and/or control signals between the RDHD and the MDVR, and which provide power to the RDHD, and control signals to turn on and off the power to the HDD on the RDHD. Removable Dual Stage Hybrid drive can be removed from the MDVR easily by opening a door on the MDVR using mechanical and/or electronic keys and/or by loosening one or two screws that hold the RDHD onto the MDVR.
[0011] A Fixed Dual Stage Hybrid Drive is a digital storage device that may comprise of one or more print circuit board; one or more HDD connector/s; one or more SSD; and may or may not have SSD Connectors; one or more HDD/s; and one or more connectors to the MDVR, which provide the interface and control signals between the Fixed Dual Stage Hybrid Drive and the MDVR, and which provide power to the Fixed Dual Stage Hybrid Drive, and which provide control signals to turn on and off power to the HDD on the Fixed Dual Stage Hybrid Drive. The Fixed Dual Stage Hybrid Drive can be removed from the MDVR by loosening up one or more screws on the enclosure of the MDVR.
[0012] The present MDVR has a sensor that determines whether the vehicle engine is on or off. The MDVR turns off the power to HDD and records the digital information onto FMC or onto SSD when the engine is on. The MDVR turns on the power to the HDD when the vehicle engine is off and copies new digital Information from the FMC or SSD to the HDD.
[0013] Furthermore, the present MDVR has a sensor that determines the vehicle movement. If the vehicle is moving, the MDVR turns off the power to the HDD and records the digital information onto FMC or onto SSD, when the vehicle is moving. It turns on the power to the HDD when the vehicle is not moving and then copies the digital information from FMC or SSD to HDD, and/or records to the HDD directly.
[0014] Furthermore, the present MDVR has a vibration sensor that determines and measures any vehicle vibration. The MDVR turns off the power to the HDD and records the digital information onto the FMC or onto the SSD if the vibration level is beyond a pre-specified threshold. It turns on the power to the HDD when the HDD is not subjected to excessive shock or vibration.
[0015] Furthermore, the present MDVR has a temperature sensor that determines the HDD temperature. The MDVR turns off the power to the HDD and records the digital information onto the FMC or onto the SSD when the temperature is beyond a safe pre-specified temperature range. It turns on the power to the HDD when the HDD temperature is within the safe temperature range and then copies the digital information from the FMC or the SSD to the HDD and/or records digital data on to HDD. The safe temperature range can be configured by the user.
[0016] The present invention provides a MDVR that uses less power, generates less heat, runs cooler and is more reliable than conventional MDVRs. The present MDVR can have an FMC or an SSD and HDD. The MDVR can have an FMC or SSD and a Removable Dual Stage Hybrid Drive (RDHD). The MDVR can have an FMC or SSD and a removable HDD. The MDVR can have an FMC or SSD and a Fixed Dual Stage Hybrid drive (FDSM).
[0017] The present invention has the following objectives:
a. Reduce the power consumption of the MDVR that uses an HDD as the Data Storage Device; b. Provide a Data Storage Device for MDVR that has the large storage capacity of an HDD and can have the operating conditions of an SSD or FMC; c. Increase the service life of the HDD that the MDVR uses as Data Storage Device; and d. Increase the reliability of the MDVR.
[0022] The present invention provides a MDVR that can meet the objectives of this invention and will possess a recording process that can reduce power consumption of the MDVR and can increase the reliability of the HDD.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Embodiments herein will hereinafter be described in conjunction with the appended figures provided to illustrate and not to limit the scope of the claims, wherein like designations denote like elements, and in which,
[0024] FIG. 1 shows the Mobile Digital Video Recorder MDVR with the present invention (a) the front side, and (b) the back side;
[0025] FIG. 2 shows the RDHD with the (a) connections on the front and (b) the HDD and FMC with the back panel open;
[0026] FIG. 3 shows the circuit board contained inside the RDHD; and
[0027] FIG. 4 shows the schematic view of the various connections of the MDVR.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Referring to FIG. 1 the overall structure of the MDVR 1 comprises of an RDHD 30 connected to a host MDVR. The casing of the MDVR 10 and RDHD 30 can be made of metal, plastic or other comparable material. The RDHD 30 can be removed slidably from the MDVR. For security purposes, the RDHD 30 can be secured using a door 31 and a lock 32 and key mechanism. The MDVR contains a plurality of connections in the back 33 and in the front 33 . The host MDVR 2 is connected to the RDHD 30 , and monitors the sensors of the DHD and regulates the function of the HDD 13 .
[0029] Again referring to the FIG. 1 , the panel is shaped and sized to receive an RDHD 30 , wherein the RDHD 30 is mounted slidably and detachably onto the panel. A locking system for securing the RDHD 30 onto the host MDVR 2 is installed on the panel 15 . The locking system may comprise of a door 31 , connected on the panel host MDVR 2 with a set of hinges. The door 31 may be closed and locked after RDHD 30 is installed in place. The RDHD 30 can be removed from the device and it can be connected to a personal computer for transferring the data.
[0030] Referring to FIGS. 1-4 The MDVR 1 comprises of an RDHD 30 connected to a host MDVR 2 . The RDHD 30 contains an HDD 13 and an FMC 14 or SSD 11 . The RDHD 30 may contain only an HDD 12 , or may have an HDD 12 and Flash Memory Card 13 or Solid State Drive 14 . Alternate embodiments may also have the RDHD be permanently fixed to the host MDVR 2 . The RDHD is connected to the host MDVR 2 by the connector 16 . The connector 16 provides a USB or a SATA signal interface between the host MDVR 2 and the RDHD 30 . The connector 16 also provides control signals 50 and power 51 to the RDHD 30 . The MDVR 10 turns on or turns off power 51 to DSD 20 . The host MDVR 2 can use the control signals 50 to control the power switch 17 to turn on or off power to the HDD 13 on the RDHD 30 . The host MDVR 2 can use the control signals 15 to control the signal & converter and switch 17 to turn on or off data interface signals 5 to HDD 13 on the RDHD 30 .
[0031] FIGS. 2-4 show that the present invention provides an RDHD 30 comprising: a metal or plastic enclosure that houses one or more than one printed circuit board 60 with HDD connector/s 31 and with FMC 32 or SSD 33 connector/s and with a control circuit that 50 can turn on and turn off power to the HDD 13 and with one or more than one HDD 13 and with one or more than one FMC 14 or SSD 11 and with one or more than one connectors 16 to the host MDVR 2 which provide the USB interface 42 signals or SATA 43 Signals and control signals 5 between the RDHD 30 and the host MDVR 2 and which provides power 4 to RDHD 30 and which provides control signals 5 to turn on and turn off power to the Hard Disk Drive 30 on RDHD 30 . The RDHD 30 can slide out of the MDVR 10 easily by opening the door 11 of the MDVR 10 with a mechanical key and/or electronics on the lock 32 key and/or by loosening one or two screws that hold the RDHD 30 onto the host MDVR 2 . The host MDVR 2 can power off the HDD 13 and write digital data onto the FMC 14 or SSD 11 inside the RDHD 30 ; and the host MDVR 2 can power on the HDD 13 and copy data from the FMC 14 or SSD 11 to HDD 13 .
[0032] FIG. 3 shows different elements of the RDHD 30 including an FMC 14 and the print circuit board 40 . The FMC 14 is connected to a print circuit board 40 electronically. The FMC 14 may be chosen from any available small memory cards. The FMC 14 may be an SDHC Flash Memory Card or an SDXC Flash Memory Card. FIG. 2B shows the rear view of the RDHD 30 with its connector 16 to the MDVR that supplies the power to the board 40 and transfers data from all other devices shown in FIG. 4 , such as a camera 6 - 7 , GPS devices 8 and others, to the board 40 . Other connectors such as mini USB connectors 42 may also be available to connect the RDHD 30 to a computer. FIG. 4 shows the print circuit board 40 comprising of a hard drive 13 , a flash memory drive 14 , a connector 16 to the host MDVR 2 with USB or SATA interface signals 15 , power, and control signals 5 or 12 C bus or UART 43 that are mounted to the board.
[0033] As shown in FIG. 3 , the inside of the RDHD 30 comprises of a print circuit 40 board, a hard disk drive 13 , a flash memory card 14 and other electronic components that all mounted on a print circuit board 40 . All data from all elements connected to the host MDVR 2 can be stored on the HDD 13 or flash memory card 14 through the print circuit board 40 and electronic elements with the use of logic theory. The hard drive 13 and the flash memory card 14 are mounted to the board 40 . In addition, a USB HUB or SATA connector 16 and USB to SD Interface IC 19 are shown on the print circuit board 60 .
[0034] Digital information may also include digital GPS data from a GPS Receiver 8 , and digital information of vehicle temperature that may come from a vehicle temperature sensor 22 or from a CAN Bus. Digital information may also include vehicle speed that may come from a GPS Receiver 8 and/or digital information that come from CAN Bus. The host MDVR 2 may have one or more network interface to connect to IP Cameras 6 - 7 , which provide the digital format of a video and audio signal.
[0035] Using an intelligent sensor interface 12 the host MDVR 2 can gather vehicle information data. Data such as vehicle speed, battery life, oil life, fuel and other data gathered by the onboard vehicle computer can be stored by the MDVR 1 .
[0036] The data interface 16 between the host MDVR 2 and RDHD 30 can be USB signals or SATA signals. The control signals 5 are 12 C bus or UART signals or digital control signals. The host MDVR 2 monitors the vehicle's engine status to determine whether the vehicle engine is running or not. If the vehicle's engine is running, and if the MDVR 1 is set to record while the engine is running, the host MDVR 2 turns off the power to the HDD 13 and then the MDVR 1 records digital information onto the FMC 14 or SSD 11 . If the FMC 14 or SSD 11 are not available, when the vehicle's engine is not running and after the MDVR 10 has stopped recording, the host MDVR 2 turns on the power to HDD 13 , turns on the signal interface 70 to the HDD 13 , and copies the recorded digital information from the FMC 14 or SSD 11 onto the HDD 13 .
[0037] On another condition, when the host MDVR 2 monitors the vehicle's engine status to determine whether vehicle engine is running, if the vehicle's engine is running, and if the MDVR 10 is set to record while the engine is running, the host MDVR 2 turns off the power to the HDD 13 , and it records digital information onto the FMC 14 or SSD 11 . When the vehicle's engine is not running and after the MDVR 10 stops recording, the host MDVR 2 turns on the power to the HDD 13 , turns on the signal interface 70 to the HDD 13 , and copies the recorded digital information from the FMC 14 or SSD 11 onto the HDD 13 .
[0038] The MDVR 10 can also use the information from a GPS receiver 68 to determine whether the vehicle is moving. If the vehicle is moving, and if the MDVR 10 is set to record while the vehicle is moving, the host MDVR 2 turns off the power to the HDD 13 . The MDVR 10 records digital information onto FMC 14 or SSD 11 . When the vehicle is not moving and after the MDVR 10 stops recording, the host MDVR 2 turns on the power to the HDD 13 , then turns on the signal interface 70 to the HDD 13 , and copies the recorded digital information from the FMC 14 or SSD 11 onto the HDD 13 .
[0039] The host MDVR 2 can monitor the vehicle ignition signal to determine whether the vehicle engine is on. The signal is provided by the vehicle at the time of ignition. When the ignition switch is turned on to start the engine, this signal is above 5V. When the ignition switch is turned off to stop the engine, this signal is less than 5V.
[0040] An accelerometer 80 can also be used to monitor the status of the engine. When the accelerometer 80 detects a repetitive vibration created by the engine, the accelerometer 80 sends its data to the host MDVR 2 . This signal can be relayed to the vehicle using CAN Bus 69 , which is the Vehicle Bus that provides the engine status information.
[0041] The host MDVR 2 monitors an additional accelerometer 81 on the RDHD 30 to determine whether the HDD 13 is subjected to excessive shock and vibration. The host MDVR 2 also monitors the HDD 13 temperature to determine whether the HDD 13 temperature is within a safe operating condition. If the HDD 13 is not within the safe operating conditions or if the HDD 13 is subjected to excessive shock and vibration, and if the MDVR 10 is set to record, the host MDVR 2 turns off the power to the HDD 13 , and consequently, the MDVR 10 records the digital information onto the FMC 14 or SSD 11 . When the HDD 13 is found to be within a safe operating condition and when the HDD 13 is not subjected to excessive shock and vibration, the host MDVR 2 turns on the power to HDD 13 , turns on the signal interface 15 to the HDD 13 , and copies the recorded digital information from the FMC 14 or SSD 11 onto the HDD 13 and records digital information directly onto the HDD 13 .
[0042] The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
[0043] With respect to the above description, it is to be realized that the optimum relationships for the parts of the invention in regard to size, shape, form, materials, function and manner of operation, assembly and use are deemed readily apparent and obvious to those skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
|
Mobile Device Video Recorders (MDVR) are used to track the motion, position and events on various types of vehicles ranging from cars to airplanes. The present invention uses a dual stage hybrid drive (DHD) which stores data on an HDD during conditions favorable to HDD operation and stores data on FMC or SSDs during conditions outside of optimal HDD operation thresholds. Recorded data from the SSD or FMC can be transferred to the HDD while the vehicle engine is off or during times of optimum HDD function while the vehicle is operating.
| 7
|
This is a division of application Ser. No. 904,111, filed May 8, 1978.
Velvet has long been considered one of the most opulent of fabrics. It has been found in the robes, crowns and thrones of monarchs. In the past, the beauty and luxurious touch of velvet was obtained by incorporating silk into the pile of the fabric. This necessarily kept velvet from the less than well to do. Sculpturing enhances the beauty of velvets but adds further to the cost. While purists would insist that any true velvet must contain silk, synthetic velvets have recently appeared which rival the true velvets in luxury and touch at substantially lower cost. Methods of producing the ornate look of sculptured velvets at moderate costs have recently been developed. A method of sculpturing pile fabrics has been disclosed in allowed U.S. Patent Application Ser. No. 750,618, now U.S. Pat. No. 4,112,560. An apparatus for carrying out this process has been disclosed in U.S. Pat. No. 4,085,700. These applications describe a method of trimming the pile from selected regions of a pile fabric by applying a stiffening agent to the regions of the pile from which the pile is to be removed, hardening the stiffening agent and drawing the fabric past a blade which contacts the pile in both the stiffened and unstiffened regions. The unstiffened fibers deflect away from the blade without being cut, but the stiffened fibers cannot deflect away and are severed. The apparatus described in these applications is capable of sculpturing fabrics of truly moderate cost but it is relatively sensitive to defects in the fabrics being processed and requires precise adjustment to achieve commercially acceptable sculpturing. Further, this apparatus has proved rather unforgiving of small deviations from precise alignment, which sometimes caused the blade to damage the unstiffened fibers, sculpture unevenly or cut through the substrate.
Recently, improvements have been made in this apparatus which make it much more forgiving of deviations from ideal alignment. In particular, it has been found that it is very advantageous to use a blade having an asysmmetric shape for sculpturing. When a translating blade is used for sculpturing, it has proved advantageous to support the fabric either on a rotating knurled nose bar adjacent to the blade or on a rotating nose bar having a smooth center portion and a recessed portion coinciding with the selvage of the fabric to be sculptured. The recessed portion has threads cut into it which grip the selvage of the fabric and counteract the drag of the blade on the fabric.
When patterns having straight lines which coincide with either the warp or the weft of the fabric are to be sculptured, it was found that the lines were often of uneven thickness and that it was difficult to sculpture patterns with equal line width in either the warp or weft directions. These difficulties can be minimized if the screen used for printing has apertures arranged on a uniform hexagonal lattice of equilateral triangles wherein the angle between the base of each equilateral triangle and circumferential lines on the screen is substantially 15°.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side elevation illustrating a fabric sculpturing device of the present invention.
FIG. 2 is a view taken along line 2--2 in FIG. 1.
FIG. 3 is a sectional view taken along line 3--3 in FIG. 2.
FIG. 4 illustrates an alternative construction of the roller supports shown in FIG. 3.
FIG. 5 is an enlarged sectional view taken along line 5--5 of FIG. 4.
FIG. 6 is a side elevation view of an alternate nose bar for use in the sculpturing device.
FIG. 7 is an enlarged fragmentary view of FIG. 1 showing the cutting zone in more detail.
FIG. 8 is still a further enlarged fragmentary view of FIG. 1 illustrating the geometry of the blade.
FIG. 9 is a schematic view illustrating the pattern of the background design used in forming screens for use in the present invention.
FIG. 10 is a view illustrating the array of apertures formed when axes of symmetry of the background design are parallel to the lines in the pattern.
FIG. 11 is a view illustrating the array of apertures properly used for printing patterns having lines which are parallel to the warp or weft directions.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For a complete understanding of the present invention, it is advantageous to refer to the teachings of allowed U.S. Patent Application Ser. No. 750,618 and U.S. Pat. No. 4,085,700 both of which are hereby incorporated by reference.
In FIG. 1, pile fabric 10 which has been printed with stiffening agent in accordance with the teachings of the above-mentioned applications is stored in scray 12. To insure that pile fabric 10 is unwrinkled and evenly tensioned as it passes over nose bar 14 adjacent to blade 16, it is first passed over rollers 18, driven rollers 20 and then over spreader 21, roller 22, and spreader 23. Pile fabric 10 passes over nose bar 14 and is taken up by driven spreaders 24, driven rollers 26 and is stored on take up roll 28. Since it is important that pile fabric 10 be uniformly tensioned as it passes over nose bar 14 and to avoid start up problems, band knife 30 having translating blade 16 is mounted on pivotable carriage 32, while the fabric handling system is rigidly mounted on frame 34. This makes it possible to always maintain pile fabric 10 in a tensioned state even when blade 16 is retracted to allow seams to pass.
Since blade 16 is a translating endless band, it is advantageous for it to have a slight amount of curvature so that it can easily be maintained in one position. The above-mentioned applications teach the desirability of matching the curvature of nose bar 14 to the curvature of blade 16. FIGS. 2 and 3, illustrate an especially advantageous mechanism for supporting nose bar 14 and maintaining uniform spacing between nose bar 14 and blade 16. Nose bar 14 rests upon rollers 36. Four rollers 36 are mounted on each pillow block 38. Pillow block 38 can be extended or withdrawn by adjusting positioning screw 44. By properly adjusting set screws 40, 41, 42, 46, 48, 50, 52, and 53, it is possible to orient pillow block 38 and thereby rollers 36 mounted on pillow block 38 so that the center lines of each set of rollers 36 are substantially parallel to the portion of blade 16 nearest that set of rollers 36. For example, in FIG. 2 on any pillow block 38 by turning set screws 52 and 40 counterclockwise as viewed from their respective heads while similarly turning each set screw 53 and 41 clockwise, it is possible to tilt pillow block 38 such that the right hand pair of rollers 36 is lifted slightly above the plane of the page while the left hand pair of rollers 36 is depressed slightly below the page. Similarly by turning set screw 48 counterclockwise as viewed from its head while similarly turning set screw 46 clockwise, it is possible to rotate each set of rollers 36 slightly clockwise as viewed in FIG. 2. By turning screws 40, 41, and 50 counterclockwise as viewed from their heads while similarly turning screws 42, 52, and 53 clockwise it is possible to lower the entire pillow block into the page as seen in FIG. 2. It is also possible to raise the portion of pillow block 38 nearest nose bar 14 out of the page while lowering the portion nearest set screw 44 into the page by turning set screws 40, 41, 52, and 53 counterclockwise while turning set screws 42 and 50 clockwise. This method of supporting and positioning rollers 36 makes it possible to match the curvature of nose bar 14 to the curvature of blade 16 closely.
FIGS. 4 and 5 illustrate an alternative construction for the roller supports wherein two long rollers 37 are rotatably mounted on each pillow block 39 which can be adjusted in the same fashion as pillow block 38. Whichever construction is used, it is very advantageous that the rollers be capable of exerting a bending force or moment upon the nose bar 14 when fabric 10 is tensioned. This requirement is met in the construction shown in FIGS. 2 and 3 since the rollers 36 rotatably mounted on each pillow block 38 are spaced apart by a distance which is more than three times the diameter of the nose bar 14. In FIGS. 4 and 5, the requirement is met since the length of rollers 37 on each pillow block 39 is greater than three times the diameter of nose bar 14.
In FIG. 2, nose bar 14, supported on rollers 36, has a substantially cylindrical center portion 56, a recessed end portion 58 with right hand threads 60. Recessed end portion 62 is formed in nose bar 14 at the end opposite the end in which recessed portion 58 is formed. In operation, blade 16 (not shown in FIG. 2) moves from right to left and exerts a drag on pile fabric 10 acting toward the left. Threads 60 in recessed portion 58 grip the right hand selvage of pile fabric 10 and pull it toward the right thus countering the drag of blade 16 on pile fabric 10 and reducing the tendency for pile fabric 10 to wrinkle on nose bar 14 due to the drag of blade 16. The left hand selvage is accommodated by recessed portion 62.
FIG. 6 illustrates alternative nose bar 114 which may be used in place of nose bar 14. Nose bar 114 is assembled from substantially cylindrical core 64 having internally threaded ends, smooth surfaced hollow cylindrical thick rings 66, knurled hollow cylindrical thick rings 68 and internally threaded smooth end portions 72. The nose bar is assembled by threading one end portion 72 into core 64, sliding a plurality of alternate smooth thick rings 66 and knurled thick rings 68 cover core 64, and threading end portion 72 into core 64. Smooth thick rings 66 coincide with rollers 36 and are hardened so they are not damaged by pressing against rollers 36 while knurled thick rings 68 grip fabric 10 and counteract the drag of blade 16. Ideally, the outer diameter of the projections or knurled rings 68 will be about 0.005 inches greater than the outer diameter of smooth rings 66 to prevent fabric 10 from slipping on nose bar 114. Recesses 70 formed in end portions 72 accommodate the selvages of fabric 10. This method of construction is very advantageous since it allows smooth thick rings 66 to be hardened after they are formed. It would be difficult to heat treat an entire bar after it was machined without warping it.
As shown in FIG. 7, blade 16 is confined between retainer plates 74, mounted on blade supports 76 which are mounted between support beams 78 on pivotable carriage 32.
As shown in FIG. 8, blade 16 has narrow facet 80 adjacent to face 82 which is adjacent to fabric 10 (omitted for clarity). Tip 84 of blade 16 is defined by the intersection of narrow facet 80 and wide facet 86. In preferred embodiments, the angle, B, between the normal to fabric 10 and narrow facet 80 will be between about 30° and about 60° while the included angle, A, between narrow facet 80 and wide facet 86 will be from about 75° to about 105°. The width, W, of narrow facet 80 will be less than about 1/3 the depth of the pile on the fabric to be sculptured. In more preferred embodiments, the angle, B, between narrow facet 80 and the normal to fabric 10 is about 48° plus or minus about 5°, the included angle, A, of blade 16 is about 85° plusor minus about 5° and the width, W, of narrow facet 80 is less than about 1/10 the depth of the pile of fabric 10. In still more preferred embodiments for sculpturing of pile upholstery fabrics, the width, W, of narrow facet 80 is between about 0.003 inches and 0.010 inches. In the most preferred embodiment for sculpturing of acrylic pile upholstery fabrics, the width, W, of narrow facet 80 is about 0.008 inches plus or minus about 0.001 inches while the most preferred width, W, for sculpturing of polyester pile fabrics is about 0.006 inches plus or minus about 0.001 inches. It is found that when blade 16 has the geometry described above, damage to the unstiffened pile is minimized and sculpturing is relatively forgiving of both defects in the fabric and minor variations from optimum alignment of nose bar 14 with respect to blade 16.
When designs having straight lines parallel to either the warp or the weft of the fabric are printed using conventional screens, it is found that often the lines are of non-uniform width. It has been found that this problem is caused by non-uniform line patterns which result when the lines in the pattern are parallel to an axis of symmetry of the design from which the screen is made. Screens for printing are often made by coating a slightly tapered mandrel with known photo-sensitive materials. The portions of the mandrel which correspond to areas which are to be open in the screen are exposed to light while the remainder is masked so that it remains unexposed. Upon subsequent treatment and electroplating by known methods, a thin removable screen is formed having openings in the areas which were exposed to light.
The mandrel is normally masked by wrapping a negative around it. The negatives are usually sequentially exposed to a background pattern and a design pattern. A typical background pattern is shown in FIG. 9. FIG. 10 illustrates a typical pattern resulting when the lines in the design pattern are parallel to an axis of symmetry of the background pattern. Vertical line 90 is composed of a series of fully open hexagons 92 while vertical line 94 is composed of two series of partial hexagons 96 and 98. Similarly, it can be seen that horizontal line 100 is composed of an alternating series of one full hexagon 102 followed by two half hexagons 104 while horizontal line 106 is composed of a series of partial hexagons 108 and 110. If a screen such as is depicted in FIG. 10 is used for applying adhesive, the amount of adhesive applied through the openings 92 in vertical line 90 will be greater than the amount applied through the openings 96 and 98 in vertical line 94. There are two principal reasons for this effect. First, when the mandrel is plated, the smaller holes 96 and 98 in lines 94 will tend to close up more than the holes 92 in line 90. Thus, the actual total open area formed by the holes 96 and 98 in line 94 will be less than the open area of the holes 92 in line 90. Indeed, holes 98 may close up entirely. Second, even if the percentage open area of the two were the same, more adhesive would flow through the holes in line 90 since more adhesive will flow through a large hole than through two small holes even if the total area of the two small holes combined is equal to the area of the large hole. Similarly, it can be seen that more adhesive will be deposited through vertical line 90 than through horizontal lines 100 or 106. It is difficult to say whether more adhesive would be deposited through horizontal line 100 or horizontal line 106, but it is certain that in many cases the amounts deposited will differ. These effects are undesirable since uneven sculpturing usually results when more adhesive is applied to one line than another. This effect is especially noticeable when regular patterns such as checkerboards or evenly spaced stripes are sculptured.
It has been found that these effects are minimized if no axis of symmetry of the background pattern is parallel to lines in the design pattern. If the background pattern has spaced apart apertures located on the vertices of an array of uniform equilateral triangles, this requirement is met by positioning the background pattern such that there will be a 15° angle between the axis of symmetry of the background pattern and circumferential lines on the screen. FIG. 11 illustrates a screen for printing lines in both the warp and weft directions using the present invention. On the screen shown in FIG. 11, the apertures define longitudinal or weft lines 116 and 118 and circumferential or warp lines 120 and 122. It can be seen that the geometric centers of adjacent apertures are located on the vertices of an array of equilateral triangles. The term "geometric center" of an aperture is to be understood to indicate the point where the center of that aperture would be if that aperture were complete whether or not the actual aperture is complete. For example in line 116, the geometric center of partial hexagon 124 would be located at point 126 and the geometric center of partial hexagon 128 would be at point 130. Thus, in FIG. 11, it can be seen that apertures 124, 132, and 134 define an equilateral triangle having sides 136, 138 and 140. The angle between side 136 and the circumferential direction is substantially 15°. The angle between side 138 and the longitudinal direction is substantially 15°. The angle between side 140 and either the longitudinal or circumferential direction is substantially 45°. All of the apertures shown in FIG. 11 are located such that their geometric centers define an array of equilateral triangles each having one side which defines a 15° angle with respect to the circumferential direction, another which defines a 15° angle with respect to the longitudinal direction and a third which defines a 45° angle with respect to both the circumferential and longitudinal directions.
It is not necessary that the apertures be hexagons as long as their geometric centers are located at the vertices of a uniform array of equilateral triangles satisfying the condition set out above. In the case of apertures having generalized shapes, the geometric center of any aperture is located at the point where the center of area of that aperture would be if it were complete whether the aperture is complete or incomplete. For example, the geometric center of a partial circle would be at the center of curvature of the arc of the partial circle.
If the conditions set forth above are satisfied, lines in the warp and weft directions will be printed properly so that lines which should be of uniform width will be uniform.
|
An improved sculpturing apparatus having an asymmetric blade, improved fabric support means and an improved screen for applying stiffening agent is disclosed.
| 3
|
This application is a continuation of application Ser. No. 07/902,164, filed Jun. 22, 1992, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a purified and isolated merozoite protein derived by either conventional or recombinant means useful for the detection of Babesia equi in horses by means of a competitive inhibition enzyme-linked immunosorbent assay (CI ELISA). The instant invention likewise relates to antibodies to the protein as well as cell lines which produce the antibodies.
2. Description of the Related Art
Equine babesiosis, caused by Babesia equi or Babesia caballi, is a tick-borne hemoprotozoan disease of horses (Schein, E., 1988. Equine Babesiosis, pp. 197-208. In M. Ristic (Ed.), Babesiosis of Domestic Animals and Man. CRC Press, Boca Raton, Fla.). Clinical disease is characterized by fever, anemia, and icterus, most likely arising from hemolysis caused by merozoites, the intraerythrocytic stage of equine Babesia infection. Mortality rate is high during initial infection of horses introduced into enzootic regions, and horses which survive initial infection are protected from clinical disease upon subsequent challenge. It is hypothesized that this immunity acquired by horses in enzootic areas is the result of persistent infection.
The complement fixation test (CFT) is presently the official United States Department of Agriculture test for detecting antibody to B. equi and B. caballi. Horses with antibody to either parasite are restricted from importation into the United States. Three problems with the CFT are that (i) sera with anticomplement activity are not testable by the CFT; (it) sera which react with CFT control erythrocyte antigen cannot be evaluated by the GFT; and (iii) sera containing specific immunoglobulin G(T) [IgG(T)] antibody may yield false-negative results because IgG(T) does not fix complement by the classical pathway.
Merozoite surface proteins are known to be important in the pathogenesis of hemoprotozoan diseases because of their role in parasite recognition of, attachment to, and penetration of host erythrocytes. Antigens recognized by antibody from hosts demonstrating immunity to clinical disease during Plasmodium spp., B. rhodhaini, B. bovis, and B. bigemina infection include surface proteins of merozoites, the only blood stage of the parasite that is extracellular and directly accessible to serum antibody. It has previously been demonstrated that cattle immune to infection with B. bovis had high-titered antibody preferentially directed against four immunodominant merozoite surface proteins (Hines et al., Mol. Biochem. Parasitol. 37:1-9; 1989). Invasion of erythrocytes by merozoites of Plasmodium knowlesi was inhibited by immune sera, and inhibition of P. falciparum merozoite invasion of erythrocytes in vitro required high concentrations of specific antibodies. These observations suggest that antibody to merozoite surface proteins may block erythrocyte invasion in vivo and that these proteins should be tested as potential immunogens.
Detection of antibodies has been the method of choice for diagnosis of infection with equine Babesia spp.; however, the specificity or role of antibodies in the acquired protective immunity against clinical disease following equine Babesia infection has not thus far been determined.
Applicants have now developed a competitive inhibition enzyme-linked immunosorbent assay (CI ELISA) based on the use of a merozoite protein for detection of antibody to B. equi. The formatting of the CI ELISA overcomes the above three problems related to use of the CFT. Furthermore, a high concordance was found to exist between the CI ELISA and CFT in detecting antibody to B. equi.
SUMMARY OF THE INVENTION
The present invention relates to the discovery and use of a novel merozoite protein of Babesia equi which has been isolated and purified. This protein contains a conserved epitope that is diagnostically useful as a sensitive and specific indicator of infection by Babesia equi in horses. The isolated protein has a molecular weight of approximately 28 kDa, with the amino acid sequence having been determined as follows:
__________________________________________________________________________1 RPPVKMISKS FAFVFASIAI SSILAEEEKP KASGAVVDFQ LESIDHVTID51 KQSEEHIVYT AHEGYAVEKV KEGDSVIKTF DLKEQTPKTV VRHIKDNKPY101 VVIAVESALH LVLKKDGDKW VELEVAEFYQ EVLFKGFEAV SVDLAAAVSD151 KFTETTFGSG KKHTFKAPGK RVLKVVDGKT ELIDGDNEVV LDLELFVSSD201 NKVARVVYLY KGDGRIKEIF LKLVEKAWKR VEVKDAAETL HGINSTFPAD251 YKVVYDGFSV YGALLAVAAI AFSTLFY 277__________________________________________________________________________
The isolated and purified merozoite protein is used to prepare antibodies which are useful in immunoassays for the diagnosis of B. equi in horses. A molecular clone of the protein expressing the conserved epitope has been obtained and shown to likewise be useful in such immunoassays. This recombinant merozoite protein is designated SEQ ID NO:1.
It is an object of this invention to provide an immunological assay for B. equi in horses based upon the antigenicity of a conserved epitope of a novel merozoite protein of
It is also an object of this invention to provide hybridomas for the production of antibodies to the conserved epitope of the merozoite protein.
It is a further object of this invention to provide antibodies as immunochemical reagents for the diagnosis of B. equi in horses.
Other objects and advantages of this invention will become readily apparent from the ensuing description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1. Immunoprecipitation of 3 H-amino acid-labeled merozoite-associated proteins of B. equi with serum from experimentally infected horse H5. Shown are labeled protein profile (lane 1), preinoculation serum (lane 2), postinoculation serum (2 months after primary infection) (lane 3), and post-second inoculation serum (1 month after second infection; 3 months after primary infection) (lane 4).
FIG. 2. Immunoprecipitation of 3 H-amino acid-labeled merozoite-associated proteins of B. equi with MAb 36/133.97. Shown are postinfection serum, horse H5 (lane 1), MAb 36/133.97 (lane 2), MAb isotype control (lane 3), protein A control (lane 4), and labeled protein profile (lane 5).
FIG. 3A. Comparisons of immunoprecipitations of [ 35 S]methio-nine-labeled in vitro translation products with dilutions of sera from experimentally infected horse H5. 10 -2 dilution of H5 preinoculation serum (lane 1), 10 -2 dilution of H5 postinoculation serum (lane 2), 10 -3 dilution of H5 postinoculation serum (lane 3), 10 -4 dilution of H5 postinoculation serum (lane 4).
FIG. 3B. Comparisons of immunoprecipitations of [ 35 S]methio-nine-labeled in vitro translation products with dilutions of sera from MAb 36/133.97 (lane 1) and MAb isotype control (lane 2). Arrowheads indicate locations of 38-,28-, to 26-, and 23-kDa proteins.
FIG. 4. Comparisons of dilutions of sera from infected horses and MAb 36/133.97 in Western blots: H5 preinoculation serum, 10 -3 (lane 1) and 10 -4 (lane 2); H5 postinoculation serum, 10 3 (lane 3) and 10 -4 (lane 4); SN76N8401 (control serum from the National Veterinary Services Laboratory, Ames, Iowa), 10 -3 (lane 5) and 10 -4 (lane 6); naturally infected horse serum, 10 -3 (lane 7) and 10 -4 (lane 8); MAb 36/133.97 (lane 9); and MAb isotype control (lane 10). Arrowheads indicate locations of 44-, 36-, 34-, and 28-kDa proteins.
FIG. 5. Immunoprecipitation of [ 35 S]methionine-labeled in vitro translation products with 1:10 dilutions of sera yielding discrepant results in the CFT and CI ELISA. Lanes 1 to 5 represent sera which tested CFT(-) and CI ELISA(+), HS, 8, 17, 113, and 175, respectively. Lane 6, SN76N8401, CFT(-) control serum. Lanes 7 to 11 represent sera which tested CFT(+) and CI ELISA(-), 18, 22, 126, 167, and 171, respectively. Lane 12, serum 236, CFT(-) and CI ELISA(-). Numbers on left show size in kilodaltons.
FIG. 6. Immunoprecipitation of [ 35 S]methionine-labeled in vitro translation products with 1:10 dilutions of equine sera with anticomplement activity or reactivity with CFT erythrocyte control antigen. Lanes: 1, serum H5; 2, serum 2, CFT(-) CI ELISA(-); 3 to 6, sera 215, 216,140, and 146, respectively, CFT (+) CI ELISA(+); 7, serum 213, anticomplement, CI ELISA(+); 8 and 9, sera 240 and 245, respectively, anticomplement, CI ELISA(-); 10, SN76N8401, CFT(-) control serum; 11, serum 238, reactive with CFT erythrocyte control, CI ELISA(+). Numbers on left show size in kilodaltons.
FIG. 7. Is the plasmid pBluescript™II SK(+/-)phagemid.
DETAILED DESCRIPTION OF THE INVENTION
In the present invention a novel protein isolated and purified from the merozoite of B. equi has been discovered and proven to be a sensitive and specific indication of the presence of antibodies to B. equi in horses. The novel protein of the invention is effective for use in immunoassays such as the competitive inhibition enzyme-linked immunosorbent assay (CI ELISA). Samples used in the test may be obtained from the serum of the horse to be tested. Immunoprecipitation of B. equi merozoite proteins recovered from an infected horse were found to have apparent molecular masses of 210, 144, 108, 88, 70, 56, 44, 36, 34, 28 and 25 kDa. The descri 36/133.97 was found to react with a protein epitope on the 44-, 36-, 34-, and 28-kDa merozoite antigens. This monoclonal antibody, 36/133.97, has been deposited under the Budapest Treaty in the American Type Culture Collection (12301 Parklawn Drive, Rockville, Md., 20852, USA) on Jan. 10, 1995, and has been assigned Deposit Number ATCC HB11788. Applicants found, through a competitive binding assay, that horses infected with B. equi throughout the world consistently produce antibodies to the antigens associated with this epitope. The 28-kDa antigen was found to be of particular interest due to its immunodominance in infected horses as recognized by MAb 36/133.97 in serum dilution studies. This protein was subsequently determined to possess the amino acid sequence:
__________________________________________________________________________1 RPPVKMISKS FAFVFASIAI SSILAEEEKP KASGAVVDFQ LESIDHVTID51 KQSEEHIVYT AHEGYAVEKV KEGDSVIKTF DLKEQTPKTV VRHIKDNKPY101 VVIAVESALH LVLKKDGDKW VELEVAEFYQ EVLFKGFEAV SVDLAAAVSD151 KFTETTFGSG KKHTFKAPGK RVLKVVDGKT ELIDGDNEVV LDLELFVSSD201 NKVARVVYLY KGDGRIKEIF LKLVEKAWKR VEVKDAAETL HGINSTFPAD251 YKVVYDGFSV YGALLAVAAI AFSTLFY 277__________________________________________________________________________
hereby designated as SEQ ID NO:1.
The mRNA associated with the 28 kDa merozoite protein of B. equi, as isolated in Example II, may be used as a template in the synthesis of cDNA by conventional techniques such as those described by Maniatis (1982, Molecular Cloning: A Laboratory Manual. Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y.), herein incorporated by reference.
The selected vector may be cut with an appropriate restriction enzyme, ligated via conventional techniques to the ends of the fragments of B. equi cDNA, and inserted into a host microorganism resulting in the synthesis of the 28 kDa protein referred to hereinabove. Without being limited thereto, suitable techniques for the preparation of vectors and transformed microorganisms are described by Drummond et al., U.S. Pat. No. 5,041,378, issued Aug. 20, 1991; the contents of which are herein incorporated by reference.
The antigen may be employed for the generation of hybrid cell lines producing MAb's specific thereto. Establishing the antibody-secreting cell lines for use in the invention is a multistep procedure which includes hyperimmunizing an animal to induce a proliferation of antibody-producing cells, promoting fusion between the primed cells and cells of an immortal cell line, selecting for antibody-secreting hybridomas, screening the hybridomas for selectability in a subsequent fusion stage, and then cloning the antibody producing hybrids. The practitioner skilled in the art would recognize that hybrid cell lines could be produced by conventional techniques. Suitable techniques for the generation of hybrid cell lines include those described by Kohler and Milstein (Nature; Vol. 256; pp. 495-497; 1975); herein incorporated by reference; and Stites (Clinical Laboratory Methods for Detection of Antigens and Antibodies. In Basic and Clinical Immunology; Stites et al. (Ed.) Lang Medical Publications, Los Altos, Calif., 1984, pp. 350-351). Without being limited thereto, particularly preferred is, the hybrid cell line producing MAb 36/133.97 discussed in Example IV below. The resultant MAb produced from the cell line binds selectively with B. equi.
It is envisioned that the monoclonal antibody (MAb) specific for the 28 kDa merozoite protein of this invention may be employed for the detection of infection by B. equi in clinical specimens, particularly serum, by use of conventional immunoassay techniques. Such an immunoassay would comprise the steps of: A) collecting serum from a horse to be tested; B) contacting the serum with antibodies specific for a conserved epitope of a merozoite protein of B. equi; and C) detecting the presence of the antigen-antibody complex. While the skilled practitioner will recognize that suitable immunoassay techniques include IFA, immunoelectrophoresis and Western Blot; enzyme-linked immunosorbent assays (ELISA) are preferred, with competitive inhibition enzyme-linked immunosorbent assays (CI ELISA) as described in Knowles et al. (Infect. Immun. 59:2412-2417, 1991), herein incorporated by reference, being most preferred.
The present invention is not limited to any specific separation or identification methodology. Rather, all modifications obvious to one skilled in the art are envisioned and encompassed by the present invention. The following examples are offered to illustrate the present invention and are not intended to limit its scope.
EXAMPLE I
Babesia equi isolates
A B. equi isolate was obtained in 1976 from a horse in Florida and cryopreserved as a blood stabilate containing 10% dimethyl sulfoxide in liquid nitrogen. A nonsplenectomized horse (H5) was infected with 30 ml of the Florida B. equi first-passage stabilate containing 5.6×10 6 viable organisms per ml. Viability was determined by incubating merozoites with fluorescein diacetate (FDA) as described by Rotman et al. (Proc. Natl. Acad. Sci. USA 55:134-141; 1966). This horse was monitored for clinical disease and parasitemia. During ascending parasitemia, 200 ml of whole blood was passaged to a splenectomized horse. At peak parasitemia (49%), infected erythrocytes were collected and stored in liquid nitrogen as a blood stabilate containing packed erythrocytes 1:1 with a cryopreservant of 20% (wt/vol) polyvinylpyrrolidone and 2% (wt/vol) glucose in Puck's saline G (GIBCO Laboratories, Chagrin Falls, Ohio); see Palmer et al. (Parasitology 84:567-572; 1982). Aliquots (25 ml) of washed packed infected erythrocytes were frozen at -70° C.
The Europe isolate of B. equi was obtained from a mare from Georgia, USSR; gee Kutler et al. (Am. J. Vet. Res. 47:1668-1670; 1986). A splenectomized pony was infected with the Europe isolate, and blood smears for indirect immunofluorescence assay (IFA) were prepared.
EXAMPLE II
In vitro translation of B. equi mRNA
B. equi merozoite mRNA was isolated from infected erythrocytes by modification of methods previously described by Maniatis et al. (Molecular Cloning: A Laboratory Manual. Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y.; 1982). A 25 ml aliquot of washed packed infected erythrocytes was thawed in the presence of equal volumes of guanidinium isothiocyanate (4.0 M guanidinium isothiocyanate [Bethesda Research Laboratories, Gaithersburg, Md.], 0.1 M Tris-HCl [pH 7.5], 1% 2-mercaptoethanol, 2% SARKOSYL® (N-Lauroylsarcosine, sodium salt) 0.01 M EDTA [pH 7.6]). Lysates were sequentially extracted with buffered phenol, phenol-chloroform-isoamyl alcohol, and ether before nucleic acids were ethanol precipitated. Polyadenylated mRNA was isolated by POLY(U)SEPHADEX® (Bethesda Research Laboratories) chromatography. In parallel, mRNA was isolated from 25 ml of washed packed uninfected erythrocytes. Stained smears of washed infected erythrocytes revealed less than 1 leukocyte per 10 4 erythrocytes. Integrity of mRNA was evaluated by the migration of rRNA species in 1% agarose gel. Merozoite mRNA was translated in vitro (Promega, Madison, Wis.), using 2 μg of polyadenylated mRNA per reaction and a nuclease-treated rabbit reticulocyte lysate; see Jackson et al. (Methods Enzymol. 96:50-71; 1983) and Pelham et al. (Eur. J. Biochem. 67:247-256; 1976). The rabbit reticulocyte lysate was chosen because it lacks microsomal membranes necessary for processing events such as signal peptide cleavage and core glycosylation.
EXAMPLE III
Radiolabeling of B. equi proteins
Defibrinated blood from a splenectomized horse infected with the Florida isolate of B. equi was collected when ascending parasitemia reached 5%. Erythrocytes were washed twice in Puck's saline G to remove the majority of buffy coat cells. A final wash was made in serum- and amino acid-free medium 199 (Hazleton Laboratories, Lenexa, Kans.). Short-term cultures were established in 2.5-cm 2 flasks at a 10% erythrocyte suspension in amino acid-free medium 199 containing 40% autologous, preinoculation horse serum, 1% penicillin G, streptomycin, amphotericin B, 25 μCi (500 μCi total) each of tritiated isoleucine, lysine, tyrosine, valine, and arginine per ml (respective specific activities, 110.8, 97.4, 46.7, 64.6, and 53.3 Ci/mmol; Dupont-New England Nuclear, Boston, Mass.) and buffered with 10 mM 3-[N-tris-(hydroxymethyl)methylamino]-2-hydroxy propanesulfonic acid, pH 7.35. Metabolic labeling proceeded during an 18-h incubation period at 37° C. in 5% CO 2 and ambient air. The labeled cells were then washed and solubilized as described by McElwain et al. (J. Immunol. 138:2298-2304; 1987). In vitro translation products were labeled with [ 35 S] methionine at 0.8 mCi/ml per reaction.
EXAMPLE IV
Production of monoclonal antibody (Mab)
Eight-week-old BALB/c mice were immunized subcutaneously with 10 7 viable merozoites in 0.1 ml of phosphate-buffered saline (PBS) emulsified in an equal volume of Freund's complete adjuvant. Merozoites for MAb production were prepared from stabilates containing a 49% parasitemia. The stabilates were diluted with 2 volumes of PBS and centrifuged at 2,500×g for 5 min. Pellets were lysed for 30 s with an equal volume of distilled water, diluted with 3 ml of PBS, vortexed gently, and centrifuged at 400×g for 5 min. The supernatant was centrifuged at 2,500×g to pellet the merozoites. Two additional immunizations consisting of the same number of parasites in incomplete Freund's adjuvant were given subcutaneously at 10-day intervals. The mice were then immunized intravenously with 10 7 viable merozoites in 0.1 ml of PBS 72 h prior to fusion. Cell fusions and cloning by limiting dilution were performed utilizing x63-A68.653 murine myeloma cells utilizing methods described by Riggs et al. (J. Immunol. 143:1340-1345; 1989). The CI ELISA used an IgG1 MAb (36/133.97) which reacts with a protein epitope on the surface of B. equi merozoites as disclosed by Knowles et al. (Infect. Immun. 59:2412-2417; 1991). Heavy-chain isotypes were identified by enzyme-linked immunosorbent assay (ELISA), and concentrations of antibodies were determined by immunodiffusion; as described by Johnstone et al. (1982, Precipitation Techniques in Agar and Agarose, pp. 120-140. In A. Johnstone and R. Thorpe (Ed.), Immunochemistry in Practice. Blackwell Scientific Publications, Boston). Supernatants from the initial fusion and from limiting-dilution clones were screened by IFA with acetone-fixed B. equi organisms.
EXAMPLE V
Immune sera from horses experimentally and naturally infected with B. equi
Serum was obtained from an adult horse (H5) infected intravenously twice at a 2-month interval with a Florida isolate of B. equi. After 50 ml of serum was obtained, the initial inoculation of H5 was with 30 ml of a first-passage stabilate of a Florida isolate of B. equi. This stabilate in 10% dimethyl sulfoxide contained 5.6×10 6 viable merozoites per ml. The second inoculation was with a 2.0-ml stabilate containing a 49% parasitemia prepared as described for B. equi isolates. Equine sera that tested positive for antibodies to B. equi by the complement fixation test; see Hirato et al. (Jpn. J. Vet. Sci. 7:197-205; 1945) were obtained from the National Veterinary Services Laboratory, U.S. Department of Agriculture, Ames, Iowa. These sera were obtained from horses in 19 countries, the data regarding such are herein presented as Table 1.
TABLE I______________________________________CI ELISA for assessment of antibodies to B. equi merozoiteproteins recognized by MAb 36/133.97Country of OD at serum dilution of .sup.a :origin 10.sup.-1 10.sup.-2 10.sup.-3 10.sup.-4 CI titer.sup.b______________________________________Argentina 0.252 0.483 1.130 1.027 10.sup.-2Austria 0.563 0.703 0.826 0.948 10.sup.-2Brazil 0.126 0.236 0.641 0.824 10.sup.-3Chile 0.650 0.866 1.241 1.315 10.sup.-1Colombia 0.180 0.713 1.259 1.191 10.sup.-2Ecuador 0.247 0.543 1.055 1.263 10.sup.-2England 0.292 0.816 1.233 1.237 10.sup.-1France 0.238 0.608 1.110 1.229 10.sup.-2Italy 0.378 0.804 1.181 1.292 10.sup.-1Netherlands 0.148 0.266 0.740 1.093 10.sup.-2North Yemen 0.663 0.851 1.166 1.193 10.sup.-1Panama 0.240 0.484 1.066 1.139 10.sup.-2Peru 0.185 0.540 1.012 1.077 10.sup.-2Poland 0.601 1.000 1.247 1.185 10.sup.-1Saudi Arabia 0.420 0.771 1.218 1.266 10.sup.-1Spain 0.295 0.607 0.687 0.733 10.sup.-3Trinidad 0.269 0.594 1.143 1.227 10.sup.-2United States 0.202 0.377 1.012 1.264 10.sup.-2Venezuela 0.325 0.771 1.244 1.324 10.sup.-1______________________________________ .sup.a OD of MAb 36/133.97 reaction with B. equi merozoites with equine serum at the specified dilution. OD for isotype control MAb with B. equi merozoites = 0.153 ± 0.05 (n = 8). .sup.b Dilution of serum reducing OD values to less than 3 standard deviations below the mean for control horses (<0.73) in CI ELISA with MAb 36/133.97. OD for control horses at a 1/2 dilution = 0.97 ± 0.08 (n = 68). Controls included preinoculation sera of H5 and SN76N8401 (control serum from the National Veterinary Services Laboratory, Ames, Iowa).
EXAMPLE VI
Immunoprecipitation and SDS-PAGE
Immunoprecipitation of radiolabeled antigen was performed as previously described by McElwain et al. (J. Immunol. 138:2298-2304; 1987). A total of 1×10 6 to 2×10 6 trichloroacetic acid-precipitable counts of antigen and 10 μg of MAb or 10 μl of equine immune serum were used in each precipitation. Immune complexes were precipitated with protein A (Pansorbin; Calbiochem, San Diego, Calif.) or protein G (Immu-Bind; Genex, Gaithersburg, Md.). Metabolically radiolabeled antigen, in vitro-translated proteins, or immunoprecipitates were boiled for 3 min in sodium dodecyl sulfate (SDS)-polyacrylamide gel electrophoresis (PAGE) sample buffer (final concentrations of 25 mM Trio [pH 6.8], 2% [wt/vol] SDS, 15% [vol/vol] glycerol, 2.5% 2-mercaptoethanol, and a few crystals of bromophenol blue) and were electrophoresed in a 7.5 to 17.5% SDS-polyacrylamide gradient slab gel with a 5% stacking gel; (see Takacs, B. 1979. Blectrophoresis of Proteins in Polyacrylamide Slab Gels, pp. 81-105. In I. Lefkovits and B. Pernis (Ed.), Immunological Methods. Academic Press, Inc., N.Y.). SDS-polyacrylamide gels were processed for autoradiography as described previously. 14C-labeled standards used for molecular weight comparisons (Amersham, Arlington Heights, Ill.) consisted of myosin (200,000), phosphorylase b (92,500), bovine serum albumin (69,000), ovalbumin (46,000), carbonic anhydrase (30,000), and lysozyme (14,300).
EXAMPLE VII
Western immunoblotting
Western blotting was performed on a miniblotter 25 (Immunetics, Cambridge, Mass.) by modification of the techniques of Towbin et al. (J. Immunol. Methods 72:313-340). Merozoite antigen was prepared from stabilates containing a 49% parasitemia as described for MAb production. Control erythrocyte antigen was prepared identically to merozoite antigen and was obtained from stabilates prepared from an uninfected horse. Pelleted merozoites were added to equal volumes of SDS-PAGE sample buffer and boiled for 10 min. Merozoite proteins separated in SDS-PAGE (as previously described) were electrophoretically transferred overnight to nitrocellulose filters in 25 mM Tris-190 mM glycine buffer containing 20% (vol/vol) methanol. Filters were blocked for 2 h in 0.17 M NaCl-0.01 M Trts-0.1 mM phenylmethylsulfonyl fluoride-1.0% (wt/vol) bovine hemoglobin (buffer A). Serum (50 μl) or MAb (10 μg) was diluted in buffer A with the addition of 0.1% (wt/vol) SDS-0.1% (vol/vol) TRITON X-100®-(polyethylene glycol p-isooctylphenyl ether) 1.0 mM EDTA (buffer B). Bound antibodies were detected by incubation for 1 h each in second antibody (rabbit anti-horse or rabbit anti-murine immunoglobulin) and 125 I-protein A in buffer B. Filters were washed three times in buffer B after incubation with equine serum or MAb, second antibody, and 125 I-protein A, followed by three washes in buffer B without hemoglobin before drying and autoradiography. 14 C-labeled molecular weight standards were the same as for SDS-PAGE previously described.
EXAMPLE VIII
IFA
(i) Fixed B. equi
IFA of acetone-fixed B. equi was performed as described previously by McGuire et al. (Infect. Immun. 45:697-700; 1984). Bound murine or equine antibodies were detected with fluorescein isothiocyanate-conjugated rabbit anti-mouse immunoglobulin or goat anti-horse immunoglobulin.
(ii) Live B. equi
Merozoites for live IFA were prepared from stabilates containing a 49% parasitemia as described for MAb production. Live IFA was performed by minor modification of methodology previously described by Goff et al. (Infect. Immun. 56:2363-2368; 1988). Merozoite pellets resuspended in 100 μl of PBS were incubated with 25 μg of MAb 36/133.97. After a 30-min incubation at room temperature, the cells were washed three times with 10% normal goat serum in PBS, diluted to 975 μl with normal goat serum-PBS, and added to 12.5 μg of goat anti-mouse antibody conjugated with tetramethylrhodamine isothiocyanate (Kirkegaard & Perry Laboratories, Gaithersburg, Md.). Samples were incubated for 30 min, washed three times with PBS, and mixed with 2.0 μl of a 5-mg/ml solution of FDA. Samples were incubated for 15 min, washed once with PBS, resuspended in 100 μl of PBS, and examined in a wet mount by phase and fluorescence microscopy. A total of 757 FDA-positive merozoites were examined for reactivity to MAb 36/133.97.
EXAMPLE IX
CI ELISA
A competitive inhibition (CI) ELISA was established to test for a direct relationship between proteins recognized by immune equine sera and MAb 36/133.97. Merozoites were prepared as described for MAb production. Merozoite preparations were diluted to 40 μg/μl in PBS containing 20 mM MgGl 2 and treated with an equal volume of lysis buffer (50 mM Tris [pH 8.0], 5 mM EDTA, 5 mM iodoacetamide, 0.1 mM N-Cα-p-tosyl-L-lysine chloromethyl ketone, and 1.0 mM phenylmethylsulfonyl fluoride in 1.0% NONDET-P-40®). (octylphenol-ethylene oxide condensate containing an average of nine moles ethylene oxide per mole of phenol) Lysates were placed on ice for 15 min and then centrifuged at 1,500×g for 15 min, and the supernatant was collected. Four microliters of supernatant adjusted to 0.20 μg of protein per μl was added to individual wells of IMMULON-2® (96 well, non-reactive plastic flat-bottom plates (Dynatech Laboratories, Chantlily, Va.) and incubated overnight at room temperature. Each well was blocked for 2-h with 350 μl of 20% milk in PBS containing 0.2% TWEEN 20® (polyoxyethylenesorbitan monolaurate) (buffer A). Equine sera were diluted in buffer A to a final volume of 290 μl and added to the wells. Samples were incubated for 30 min, 0.125 μg of MAb 36/133.97 in 10 μl of buffer A was added, and the reaction mixture was incubated for 1-h at room temperature. Wells were washed three times with PBS containing 0.2% TWEEN 20 (buffer B). Biotinylated equine anti-murine immunoglobulin G (IgG; Vector Laboratories, Burlingame, Calif.) in buffer A was added, incubation was continued for 30 min, and the wells were washed three times with buffer B. Addition of avidin-conjugated alkaline phosphatase (Vector Laboratories) in buffer B was followed by a 30-min incubation. Wells were washed three times with buffer B, and 100 μl of a 1.0-g/μl solution of p-nitrophenyl phosphate in 100 mM NaHCO 3 (pH 9.5) with 10 mM MgCl 2 (Sigma Laboratories, St. Louis, Mo. ) was added to each well. Following a 30-min incubation, reactions were stopped with 50 μl of 0.2 M EDTA and the optical density (OD) was read at 405 nm on a Dynatech MR-5000 ELISA plate reader.
EXAMPLE X
Immunoprecipitation of B. equi merozoite proteins with equine serum
FIG. 1 shows immunoprecipitation of B. equi merozoite proteins with pre- and postinoculation serum from horse H5 infected with a Florida isolate of B. equi. The major B. equi merozoite proteins recognized by antibodies from this horse have apparent molecular masses of 210, 144, 108, 88, 70, 56, 44, 36, 34, 28, and 25 kDa. Immunoprecipitations with sera from 10 additional experimentally infected and 2 naturally infected horses provided similar results.
EXAMPLE XI
Immunoprecipitation of B. equi antigens with MAb 36/133.97
An autoradiograph comparing immunoprecipitation of merozoite proteins with MAb 36/133.97 and equine immune serum is shown in FIG. 2. MAb 36/133.97, isotyped as IgGl, immunoprecipitated proteins with approximate molecular masses of 44, 36, 34, and 28 kDa which comigrated with proteins immunoprecipitated by serum from infected horse H5.
EXAMPLE XII
IFA of fixed and live merozoites with MAb 36/133,97
The epitope recognized by MAb 36/133.97 is conserved on at least two isolates of B. equi, as determined by reactivity in IFA. MAb 36/133.97 reacted with both the Florida and Europe; see Kutler et al. (Am. J. Vet. Res. 47:1668-1670, 1986), isolates of B. equi at a final concentration of 0.66 μg/ml. Up to 100% of merozoites from the Florida and Europe isolates of B. equi reacted with MAb 36/133.97 in fixed IFA. MAb 36/133.97 did not react with uninfected erythrocytes or B. caballi in IFA. At the same concentrations, IgG1 isotype control MAb and rabbit anti-mouse second antibody did not react with B. equi-infected erythrocytes. The surface reactivity of MAb 36/133.97 was demonstrated by its binding to viable (FDA-positive) merozoites. Approximately 80% of isolated merozoites stained with FDA and 64% (482 of 757) of FDA-positive merozoites reacted diffusely with MAb 36/133.97.
EXAMPLE XIII
Protein character of the epitope and immunodominance of the protein recognized by MAb 36/133.97
Equal volumes of washed packed erythrocytes from infected and uninfected horses yielded 5.7 and 0.22 μg of polyadenylated RNA. The small amounts of polyadenylated RNA isolated from uninfected erythrocytes provided insufficient incorporation of [ 35 S]methionine from in vitro translation for use in immunoprecipitations. Immunoprecipitation of in vitro-translated B. equi mRNA with serum from infected horse H5 and with MAb 36/133.97 is shown in FIG. 3A and 3B. MAb 36/133.97 immunoprecipitated proteins at 38, 28, 26, and 23 kDa (FIG. 3B, arrowheads) which comigrated with proteins immunoprecipitated by serum from horse H5 at 10 -3 to 10 -4 dilutions (FIG. 3A). In vitro translation products derived from rabbit reticulocyte lysate are not glycosylated. Therefore, immunoprecipitation of these products by MAb 36/133.97 indicates that the binding site recognized by this antibody is a protein epitope. Immunoprecipitation of in vitro-translated B. equi mRNA with sera from four naturally infected horses provided similar results.
In Western blot analysis, MAb 36/133.97 did not react with antigen from uninfected erythrocytes; however, it recognized proteins of 44, 36, 34, and 28 kDa prepared from stabilates of infected erythrocytes (FIG. 4, arrowheads). Evaluation of diluted horse sera demonstrated reactivity with a 28-kDa protein at a dilution of 10 -4 as also seen in FIG. 4.
EXAMPLE XIV
Relatedness of proteins recognized by sera from B. equi infected horses and MAb 36/133,97
Relatedness of proteins recognized by MAb 36/133.97 and sera B. equi-infected horses was investigated by a CI ELISA. Sera from 34 noninfected horses allowed MAb 36/133.97 to bind in the CI ELISA with 0D values of 0.97±0.08. Thus, inhibition of MAb binding to B. equi merozoites was considered significant at OD values of <0.73, corresponding to mean OD minus 3 standard deviations. Table I shows that sera from infected horses from 19 countries significantly inhibited the binding of MAb 36/133.97 to isolated merozoites. At a 10 -1 dilution, sera from all infected horses uniformly inhibited binding in the CI ELISA. Some of these sera also inhibited the binding of MAb 36/133.97 at dilutions of 10 -2 and 10 -3 .
EXAMPLE XV
One hundred fifty-four equine serum samples from 19 countries in North America (6 samples), South America (113 samples), Europe (28 samples), and the Middle East (7 samples) were obtained from the National Veterinary Services Laboratory, USDA-APHIS, Ames, Iowa. Each serum was tested for antibody to B. equi by the CFT as described by Frerichs et al. (Am. J. Vet. Res. 30:697-702, 1337-1341; 1969). Three anticomplement serum samples and one serum sample reactive with the CFT erythrocyte antigen control were also obtained from the National Veterinary Services Laboratory. H5 serum is from a horse experimentally infected with stabilate of a Florida B. equi isolate as disclosed by Knowles et al. (Infect. Immun. 59:2412-2417; 1991) and SN76N8401 is a GFT-negative control serum obtained from the National Veterinary Services Laboratory. One hundred and four equine serum samples submitted to Washington State University for equine infections anemia testing were used as control sera.
A CI ELISA was performed on all samples utilizing applicants' recombinant antigen preparation of Example in conjunction with the protocol set forth in Example IX. Serum samples were tested by CI ELISA in groups of 5 to 15 per day without knowledge of the CFT results. Duplicates of each serum sample were tested at dilutions of 1:2 and 1:10. Five to 10 different control serum samples were tested at a 1:2 dilution in duplicate each day. A mean and standard deviation of the OD for the control serum samples was calculated following each test day. A serum sample was considered positive for antibody to B. equi if it inhibited the binding of MAb 36/133.97 such that the mean duplicate OD value for that dilution of test serum as at least 3 standard deviations below the mean OD value of the control serum samples for that test day. Sample data from the CI ELISA and CFT for a test day are given in Table 2.
TABLE II______________________________________Sample data from CI ELISA and CFT.sup.aCI ELISA, OD.sup.b CFT titer.sup.cSerum 1:2 1:10 B. equi B. caballi______________________________________224 0.381, 0.389 0.382, 0.441 1:5 1:40225 0.471, 0.486 0.732, 0.721 1.5 Negative226 1.489, 1.470 1.717, 1.672 Negative 1:5227 1.337, 1.369 1.146. 1.619 Negative 1:40228 0.217, 0.156 0.229, 0.236 1:40 1:20229 0.301, 0.298 0.336, 0.363 1:5 1:40230 1.374, 1.362 1.560, 1.528 Negative 1:5231 0.356, 0.356 0.439, 0.426 1:40 1:5232 0.219, 0.254 0.334, 0.313 1:5 Negative233 0.246, 0.260 0.351, 0.389 1:5 1:10234 0.521, 0.486 0.761, 0.736 1:10 Negative235 0.189, 0.198 0.314, 0.383 1:40 1:10236 1.380, 1.351 1.535, 1.384 Negative 1:40237 0.347, 0.277 0.465, 0.345 1:5 1:40238 0.314, 0.308 0.461, 0.470 * *H5 0.293, 0.303 ND.sup.d Negative Negative______________________________________ .sup.a CI ELISA and CFT were performed as described in the text. .sup.b Serum samples reducing mean of duplicate OD values to less than 3 SD below mean of control horses (<1.17) were considered positive. OD for control horses at a 1:2 dilution on this test day = 1.47 ± 0.10 (SD) ( = 9). OD for isotype control MAb = 0.145, 0.142. .sup.c CFT titers are presented at the highest dilution yielding a positive result. *, serum sample which reacted with CFT erythrocyte control antigen. .sup.d ND, not done.
Of the 154 serum samples testable by CFT, 126 were both CFT and CI ELISA positive [CFT(+) CI ELISA(+)] for antibody to B. equi. Eighteen serum samples were negative in both tests, and CFT and CI ELISA results differed in the remaining 10 serum samples. Sixteen of the 18 serum samples negative by both the CFT and CI ELISA for antibody to B. equi were CFT(+) for B. caballi.
The ten serum samples in which the CI ELISA and CFT results differed were retested in both assays and analyzed by immunoprecipitation. CI ELISA, CFT,and immunoprecipitation results for the 10 discrepant serum samples are summarized in Table 3. Upon retesting, four of the CFT(+) CI ELISA(-) serum samples had decreased CFT titers. Two of these serum samples which were originally CFT(+) were negative in the repeat CFT. The decreasing CFT titers of these serum samples may reflect, at least in part, multiple freeze-thaw cycles.
TABLE III______________________________________CI ELISA, CFT, and immunoprecipitation results ofsera differing on initial testing.sup.aCFT CI ELISA Immunopre-Serum Original Repeat Original Repeat cipitation______________________________________8 Negative Negative Positive Positive Positive17 Negative Negative Positive Positive Positive113 Negative Negative Positive Positive Positive175 Negative Negative Positive Positive PositiveH5 Negative Negative Positive Positive Positive18 1:10 Trace Negative Negative Inconclusive22 1:10 1:5 Negative Negative Inconclusive126 1:5 Negative Negative Negative Inconclusive167 1:40 1:40 Negative Negative Inconclusive171 1:5 Negative Negative Negative Inconclusive______________________________________ .sup.a CI ELISA, CFT, and immunoprecipitation results were determined as described in the text. Serum samples which differed in the CI ELISA and CFT at original testing were retested by CI ELISA, CFT, and immunoprecipitation. CFT titers are presented as the highest dilution yielding a positive result.
Serum samples at a 1:10 dilution were evaluated for their ability to immunoprecipitate 35 S-labeled in vitro translation products of B. equi merozoite mRNA as described by Knowles et al. (Infect. Immun. 59:2412-2417; 1991). FIG. 5 displays immunoprecipitation data from the five serum samples which were CFT(-) CI ELISA(+), the five serum samples which were CFT(+) CI ELISA(-), and two serum samples which were negative in both tests. Five serum samples which were CI ELISA(+) CFT(-) clearly immunoprecipitated multiple B. equi proteins that comigrated with proteins immunoprecipitated by positive control serum H5 (FIG. 5, lanes 1 to 5). Interestingly, serum H5, from a horse experimentally infected with B. equi and used as positive reference serum in the CI ELISA and immunoprecipitations, was one of the serum samples consistently negative by the CFT.
While B. equi-specific IgG(T) antibody was not measured in the five CI ELISA(+) CFT(-) serum samples, IgG(T) remains a likely explanation for the false-negative CFT results. It has been previously shown that IgG(T) specific for equine infectious anemia virus inhibits the CFT for detecting antibody to equine infectious anemia virus because IgG(T) does not fix complement by the classical pathway disclosed by McGuire et al. (J. Immunol. 107:1738-1744; 1971).
Immunoprecipitation results with the five serum samples which were GI ELISA(-) CFT(+) were inconclusive (FIG. 5, lanes 7 to 11). Fewer proteins were immunoprecipitated by these serum samples than by H5 serum. However, proteins not present in the negative control serum samples (FIG. 5, lanes 6 and 12) were immunoprecipitated by the CI ELISA(-) CFT(+) serum samples. The results obtained from the five CI ELISA(-) CFT(+) serum samples may represent false-positive GFT results; however, the immunoprecipitation results show reactivity with B. equi merozoite proteins (FIG. 5, lanes 7 to 11). Three of these serum samples (22, 126, 171) also had CFT titers to B. caballi, and t immunoprecipitation results with these serum samples may reflect serological cross-reactivity between B. equi and B. caballi merozoite proteins as previously recognized by Frerichs et al. (Am. J. Vet. Res. 30:697-702; 1969).
If the five CI ELISA(-) CFT(+) serum samples are true positives, there are at least three possible explanations: (i) a genetic inability of those horses to produce antibody to the epitope defined by MAb 36/133.97; (ii) absence of the epitope on B. equi isolates which infected those horses; and (iii) insufficient CI ELISA sensitivity. The third explanation does not seem likely since 32 of the CFT(+) CI ELISA(-) serum samples had CFT titers of only 1:5.
Three anticomplement serum samples and one serum sample which reacted with the CFT erythrocyte control antigen were tested by the CI ELISA and immunoprecipitation are shown in FIG. 6. Immunoprecipitations with these serum samples were compared with immunoprecipitations with H5 serum, four randomly selected CI ELISA(+) CFT(+) serum samples, and two serum samples negative by both tests (FIG. 2). One of three anticomplement serum samples and the serum sample reactive with CFT erythrocyte control antigen were positive by both CI ELISA and immunoprecipitation (FIG. 6, lanes 7 and 11). Two anticomplement serum samples were CI ELISA(-), and one of these serum samples was clearly negative by immunoprecipitation (FIG. 6, lane 9). Lane 8 of FIG. 6 represents immunoprecipitation with the additional anticomplement serum which was CI ELISA(-). Data obtained from this immunoprecipitation were inconclusive. The proteins in lane 8 not found in the control serum samples (lanes 2 and 10) may signify cross-reactivity between antigens of B. equi and B. caballi. Also, this serum may represent a false CI ELISA(-).
The collective data of this report indicate a high (94%) concordance between the CI ELISA and CFT for detecting antibody to B. equi. Since 16 of 18 serum samples in this study which were CI ELISA(-) CFT(-) for antibody to B. equi were CFT(+) for antibody to B. caballi, the CI ELISA is clearly specific for B. equi. Furthermore, the formatting of the CI ELISA overcomes the aforementioned limitations associated with the CFT, and as the data clearly indicate, the geographic conservation of the epitope recognized by MAb 36/133.97 allows reliable use of the CI ELISA to detect B. equi antibody in sera from horses worldwide.
EXAMPLE XVI
Construction and expression of cDNA library
B. equi merozoite mRNA was isolated from infected erythrocytes as previously described in Example II. cDNA library construction was performed utilizing the methods of Maniatis et al. (1982. Molecular Cloning: A Laboratory Manual. Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y.). In this process 2 μg of merozoite mRNA were copied by reverse transcriptase followed by T4 polymerase (pharmacia). The resultant DNA was blunted, EcoRl linkers were applied and ligation into the EcoRl-site of LAMBDA ZAPII® (Stratagene Cloning Systems) was carried out. The lambda library in E. coli XL-blue was screened with MAb 36/133.97 by immunoblot assay. Transfer of bacteria to nitrocellulose was done by standard procedures and recombinant protein was detected using MAb 36/133.97 (2 μg/ml), rabbit anti-mouse second antibody and 125 I protein A. Positive plaques were isolated, replated and rescreened to achieve purity. Recombinant plasmids were excised from the bacteriophages and following induction with 5 mM isopropyl-1-B-D-thiogalactopyranoside (IPTG), tested for expression by immunoblot assay.
EXAMPLE XVII
Plasmid purification via cesium chloride
The bacterial suspension containing pBluescript/10E3; which has been deposited under the Budapest Treaty in the American Type Culture Collection (12301 Parklawn Drive, Rockville, Md., 20852, USA) on Jan. 10, 1995, and has been assigned Deposit Number ATCC 97016; was transferred to 250 ml proplyene bottles and pelletized by centrifugation in a Beckman at 7000 rpm for 20 min at 4° C. As a separate step 37.5 mg of lysozyme was dissolved in 7.5 ml of an aqueous reagent solution comprising 50 mM glucose, 25 mMTris and an HCl adjusted pH of 8.0 (Solution A). The pelleted bacteria are then suspended in the lysozyme-containing Solution A and transferred to a 50 ml polypropylene centrifuge tube. The suspension was allowed to stand at room temperature for 5 min, at which point 15 ml of an aqueous reagent solution comprising 0.2 N NaOH and 1% SDS (Solution B) was added and thoroughly mixed. The tube was then incubated on ice for 10 min before adding 11 ml of an aqueous reagent solution composed of 60 ml of 5 M potassium acetate, 11.5 ml of glacial acetic acid and 22.5 ml of distilled water (Solution C), and thoroughly mixed. The contents of the tube were then centrifuged at 17,000 rpm for 40 min at 4° C. in a polyallomer SW28 centrifuge tube. The resultant liquid phase of 32 ml was then distributed evenly between two SW28 tubes. The plasmid DNA present in the tubes was then precipitated by the addition of 9.6 ml of isopropanol to each tube and being allowed to stand at room temperature for 20 min. The plasmid DNA was then pelleted by centrifugation at 12,000 rpm for 30 min at 4° C. The pellets were then lyophilized, combined and suspended in precisely 4.3 ml of TE Buffer (pH 8.0) in a SW28 tube. 4.63 grams of CsCl was added to the sample. After equilibration at room temperature 80 μl of Ethictrium Bromide (10 mg/ml) was added and mixed thoroughly. The sample was then placed in a Ti65 polyallomer tube and heat-sealed. The tube was then centrifuged with a Vti65 rotor at 48,000 rpm for 16 hours at 20° C. After centrifugation, the plasmid band was then extracted by syringe as part of a 1.2 ml sample and expelled into a polyallomer SW41 centrifuge tube. The DNA was then precipitated by the addition of 2.4 ml of water and 7.2 ml of 95% ethanol to the 1.2 ml sample. The sample was then stored at -20° C. for one hour and then centrifuged with a SW41 rotor at 15,000 rpm for 30 min at 4° C. The pellet was then lyophilized and transferred to a 1.5 ml microcentrifuge tube where it was solubilized in approximately 300 μl of TE Buffer (pH 7.2). Approximately 30 μl of RNAse A Solution was added to the sample which was then incubated at 37° C. for 30 min. Approximately 2 μg of Proteinase K was then added to the sample which was then incubated again at 37° C. for 30 min. The sample was then extracted with phenol/chloroform. A reextraction with phenol/chloroform was then performed using 200 μl of TE Buffer (pH 7.2). The sample was then extracted with water-saturated ether. After removal of the ether phase the sample was precipitated by adding 1/10 th volume of 5 M NaCl and 3 volumes of the combined sample plus salt of 95% ethanol. The sample was then stored at -20° C.
EXAMPLE XVIII
Banahan Std. high frequency transformation
A sample of DH5 bacteria (from BRL Product Profile-see Hanahan, D., 1983, J. Mol. Biol. 166:557-580) was streaked onto SOB(Mg++) + agar and incubated at 37° C. for about 18 hours. The colonies were transferred into 1 ml SOB broth per colony. Each 1 ml cell suspension was used to inoculate a flask containing 10 ml of SOB broth. The flasks were incubated at 37° C. and 250 rpm until a cell density of at least 4×10 7 viable cells/ml was reached. The cell suspension was then cooled on ice for 10-15 min. The suspension was then centrifuged at 2000 rpm for 12 min at 4° C. to pelletize the cells. The cells were then resuspended in 3.3 ml of TFB and incubated on ice for 10 min. The cells were then repelletized by centrifugation at 2000 rpm, for 12 min at 4° C. The cells were then resuspended in 0.8 ml of SOB with TFB, adding 28 μl of DMSO and DTT to make a 3.5% concentration. The sample was then incubated on ice for 10 min and a second 28 μl portion of DMSO and DTT was added to make a final concentration of 7%. The sample was then incubated on ice for 10 min. 210 μl of the cell suspension was then combined with less than 20 μl of the DNA solution (plasmid) resulting from Example XVII and incubated on ice for 20 min. The reaction was then heat shocked in a 42° C. water bath for 90 seconds and immediately chilled on ice for 2 min. 800 μl of SOC broth was then added to the sample and allowed to incubate at 37° C. for 30 min. 500 μl of the reactant was then spread on a YT/Amp ++ plate and allowed to dry before incubation at 37° C.
______________________________________.sup.+ S.O.C./S.O.B. Preparation Amt./ 485H.sub.2 O/Reagent Conc. 100 ml 500 ml______________________________________BactoTryptone 2.0% 2.0 gm 10 gmYeast Extract 0.5% 0.5 gm 2.5 gmNaCl 10 mM 1.0 ml 1M NaCl 5.0 mlKCl 2.5 mM 0.25 ml 1M KCl 1.25 m.MgCl2.MgSO.sub.4 20 mM 1.0 ml 2M Mg Stock 5.0 ml (10 mM each)Glucose 20 mM 1.0 ml 2M Glucose 5.0 mlDistilled H.sub.2 O qs to 100 ml total volume______________________________________
S.O. Broth
Bactotryptone, yeast extract, NaCl and KCl were added to 97 ml of distilled water, dissolved and then autoclaved. MgCl 2 and MgSO 4 were then added at a rate of 1/100 to the solution.
S.O.B. Plates
Same procedure for S.O. broth but with the additional inclusion of agar to the solution at a rate of 15 g/l prior to autoclaving.
S.O.C. Broth
Same procedure for S.O. broth but with the additional inclusion of 2M glucose at a rate of 1/100 after autoclaving.
______________________________________.sup.++ YT/Amp Plate AgarReagent 1 liter 500 ml 250 ml______________________________________NaCl 5.0 gm 2.5 gm 1.25 gmBacto Yeast Extract 5.0 gm 2.5 gm 1.25 gmBacto Tryptone 8.0 gm 4.0 gm 3.0 gmBacto Agar 15 gm 7.5 gm 3.75 gm______________________________________
The first three ingredients are dissolved in the desired volume of distilled water. The agar is then suspended and autoclaved for 20-30 min.
After the agar has cooled to about 50° C., 50 mg/L of ampicillin are added to the agar Just before it is poured into the plates.
EXAMPLE XIX
Production of recombinant antigen
The purified and isolated plasmid pBluescrtpt/lOE3 resulting from the cesium chloride purification process of Example XVI (see Maniatis et al., 1982. Molecular Cloning: A Laboratory Manual. Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y.; herein incorporated by reference) was used in an amount of 1 μg to transform E. coli strain DH 5 (Bethesda Research Laboratories) using the Hanahan Standard High Frequency Transformation of Example XVIII (see Hanahan, D., 1983, J. Mol. Biol. 166:557-580; herein incorporated by reference). The entire transformation reaction was added to 250 ml of YT broth containing 12.5 mg ampicillin and 59.5 mg IPTG. The culture was incubated overnight at 37° C. and 250 rpm. The cells from the culture were then pelletized by centrifugation at 1000×g for 10 min at 4° C. The resultant pellet was then resuspended in 40 ml of Proteinase Inhibition Buffer + and recentrifuged at 1000×g for 10 min at 4° C. The resultant pellet was then resuspended in 20 ml of Proteinase Inhibition Buffer containing 1 mg/ml lysozyme and incubated on ice for 20 min. NP40 (Sigma Chemicals, #N3516) was added to 1% (200 μl) was added, and the solution was incubated on ice for 10 min. The solution was then sonicated twice at 100 watts with the probe in the solution; with each event lasting 20 min and pausing 15 min on ice between the two events. The solution was then centrifuged at 12,000×g for 10 min at 4° C. The supernatant, representing the recombinant antigen, was then recovered and stored at 4° C.
______________________________________.sup.+ Proteinase Inhibitor Buffer 100 ml 500 ml______________________________________50 mM Tris ph 8.0 606 mg 3.03 gm5 mM EDTA 186 mg 0.93 gm5 mM lodcacetamide 92.5 mg 0.46 gm0.1 Mm TLCK 3.69 mg 18.45 gm1 mM PMSF 2.27 ml 11.35 ml______________________________________
EXAMPLE XX
Coating a plate with recombinant antigen
The recombinant antigen of Example XIX was slowly vortexed then made into a 1:10 dilution by addition of 50 μl of antigen to 450 μl of coating buffer + . Two tubes of 1:100 dilution were then prepared by adding 50 μl of the 1:10 dilution to 450 μl of the coating buffer. The coating buffer was then added to the wells of a Dynatech Immulon 2 plate, skipping columns 1 and 12--the total volume of the coating buffer being added equaling 100 ml less the volume of the diluted antigen. The appropriate amount of the 1:100 dilution was then added to the coating buffer in each well. The plate was sealed and stored at room temperature overnight.
______________________________________.sup.+ Coating Buffer______________________________________To make 100 ml: Add to 75 ml d H.sub.2 O: 0.88 gm NaCl 0.02 gm KCl 0.158 gm Na.sub.2 HPO.sub.4 0.02 gm KH.sub.2 PO.sub.4 Mix and adjust pH to 7.4 with 1M HCl 0.446 gm MgCl.sub.2.6H.sub.2 O Add H.sub.2 O to bring volume to 100 ml______________________________________
__________________________________________________________________________SEQUENCE LISTING(1) GENERAL INFORMATION:(iii) NUMBER OF SEQUENCES: 1(2) INFORMATION FOR SEQ ID NO:1:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 277 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: double(D) TOPOLOGY: unknown(ii) MOLECULE TYPE: cDNA(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(vi) ORIGINAL SOURCE:(A) ORGANISM: Babesia equi(B) STRAIN: Florida(D) DEVELOPMENTAL STAGE: merozoite(vii) IMMEDIATE SOURCE:(B) CLONE: pEma1(xi) SEQUENCE DESCRIPTION: SEQ ID NO:1:ArgProProValLysMetIleSerLysSerPheAlaPheValPheAla151015SerIleAlaIleSerSerIleLeuAlaGluGluGluLysProLysAla202530SerGlyAlaValValAspPheGlnLeuGluSerIleAspHisValThr354045IleAspLysGlnSerGluGluHisIleValTyrThrAlaHisGluGly505560TyrAlaValGluLysValLysGluGlyAspSerValIleLysThrPhe65707580AspLeuLysGluGlnThrProLysThrValValArgHisIleLysAsp859095AsnLysProTyrValValIleAlaValGluSerAlaLeuHisLeuVal100105110LeuLysLysAspGlyAspLysTrpValGluLeuGluValAlaGluPhe115120125TyrGlnGluValLeuPheLysGlyPheGluAlaValSerValAspLeu130135140AlaAlaAlaValSerAspLysPheThrGluThrThrPheGlySerGly145150155160LysLysHisThrPheLysAlaProGlyLysArgValLeuLysValVal165170175AspGlyLysThrGluLeuIleAspGlyAspAsnGluValValLeuAsp180185190LeuGluLeuPheValSerSerAspAsnLysValAlaArgValValTyr195200205LeuTyrLysGlyAspGlyArgIleLysGluIlePheLeuLysLeuVal210215220GluLysAlaTrpLysArgValGluValLysAspAlaAlaGluThrLeu225230235240HisGlyIleAsnSerThrPheProAlaAspTyrLysValValTyrAsp245250255GlyPheSerValTyrGlyAlaLeuLeuAlaValAlaAlaIleAlaPhe260265270SerThrLeuPheTyr275__________________________________________________________________________
|
The present invention relates to a purified and isolated merozoite protein which is a specific indicator of infection by Babesia equi (B. equi) in horses. This protein contains a conserved region found in all strains of B. equi. It has a molecular weight of approximately 28 KDa and has been successfully purified and sequenced. The isolated and purified merozoite protein is used to prepare antibodies which can then be used in a competitive inhibition enzyme linked immunosorbent assay for the diagnosis of B. equi infection in horses.
| 8
|
FIELD OF THE INVENTION
This invention relates to test strips which may be used in pieces in combination with a bed of conventional cat box filler for detection of feline urinary tract disease.
BACKGROUND OF THE INVENTION
Feline lower urinary tract disease (FLUTD) can be a life-threatening condition for cats. In particular, the main problem that cat owners face with FLUTD is that the disease is life-threatening to the cat by the time the symptoms are noticeable to the owner. Crystals of magnesium ammonium phosphate (MAP) can precipitate in the cat's urinary tract and obstruct it. If left untreated, a “blocked” cat will die within days. Furthermore, treatment is costly and traumatic to the cat, to say nothing of the affect on the cat's owner. With early detection made possible by occult blood testing, cat owners could in theory successfully treat the problem of FLUTD simply by changing the cats' diets.
The major problem for early detection of FLUTD is that the cat owners are unsophisticated in detecting the symptoms. With the symptoms going unrecognized, often by the time the pet owner takes the cat to the veterinarian, it is simply too late.
While detection systems are available for FLUTD that rely upon occult blood testing of urine, it is a fact that it is difficult to conduct the test or even when to know one needs to conduct the test. One easy answer is to provide the test material in the cat box filler in which the cats normally urinate.
However, providing a reliable occult blood detection system in cat box filler itself has its own problems. For example, the test indicator material must be stable when exposed to a wide variety of ambient conditions varying from extremely dry, to extremely humid, all over a wide range of temperatures. Often such stability is very difficult to achieve.
Another common problem with normal test indicators is that pet owners are insufficiently observant to notice a color change before the color indicator decays. Thus a reliable indicator should stay at the changed color for a period of at least 8 hours in order for the pet owner to have a sufficient chance to observe the color change.
Another problem often occurring with test reagents mixed with the cat box filler is that the cat's sensitive sense of smell will detect any odor changes, making the cat shy away from the litter. Thus any test reagent which can be successfully mixed with cat box filler must be provided in a substantially inoffensive odor form for the cats.
Yet another common problem which must be overcome is providing a cat box filler/test reagent combination which has shelf life stability such that it can be stored in merchandisable containers for a sufficient period of time to allow transport, shelf display, purchase, and then use.
Previously-used materials and systems for detection of FLUTD have involved one or more of the above deficiencies. It is a primary object of the present invention to overcome these deficiencies with a material and system which can accurately test for FLUTD and which can be safely and reliably stored, transported, and ultimately used by the pet owner.
In particular, it is one object of this invention to provide test strip materials which can be subdivided into pieces and then conveniently homogeneously mixed with conventional cat box filler to provide a safe and reliable occult blood test for FLUTD.
Another objective of the present invention is to provide test strip materials which can be combined with cat box filler which exude only odors that are nonoffensive to the cat.
Yet another objective of the present invention is to provide a test composition which can be mixed with conventional cat box filler and still show adequate stability towards changing weather and light conditions.
An even further objective is to provide a FLUTD test composition which can be triggered for test by as few as 100 red blood cells per microliter of cat urine.
A yet further objective is to provide a litter additive composition which has a pink color in the unreacted form, since such color is found pleasing to the pet owner.
The method and manner of accomplishing each of the above objectives will become apparent from the detailed description of the invention which follows.
SUMMARY OF THE INVENTION
Test strips for detection of feline lower urinary tract disease (FLUTD) which remain stable when exposed to ambient conditions, and which provide a positive color response for at least 8 hours, are provided for use in combination with conventional cat box filler.
DETAILED DESCRIPTION OF THE INVENTION
Conventional cat box filler is typically a clay product, often having an off-white, grayish color. Such processed granular clay materials are often montmorrillonite clays, and are well known and conventionally available. The test strip materials of the present invention are designed to be cut in small pieces approximately the size of the cat box filler material so they can be easily admixed therewith without interfering with the cat's natural attraction to its litter filled cat box.
The test strip material in its simplest form is a piece of bibulous filter paper matrix of sufficient porosity and capillary affinity to cause a urinary sample from the cat to migrate into the test paper, which is coated with the test reagent. The paper matrix may be a woven or a non-woven material and may include, but is not limited to cellulosic natural fiber materials of the type normally used to make filter papers, etc. Suitable matrixes or substrate papers are available under the trademarks Gelok 3001 S/S laminate, Hollingsworth and Vose 7303 (a polyester); Walkisoft FG400 (superabsorbent paper used in diapers); Whatman 3MM; Whatman CCP500; and Ahlstrom 237. Other natural or synthetic fiber matrix materials, either woven or non-woven, may also be used, such as organic polymer materials. Satisfactory results are achieved with Ahlstrom 237, as illustrated in the examples below.
In accordance with the process of the present invention, pieces of bibulous paper are initially impregnated in a first reagent dip with aqueous components. The aqueous component composition will typically comprise a surfactant, a buffer, and preferably a color enhancer and a color stabilizer. Conventional aqueous buffers are well known and can include, for example, malonic acid and tris(hydroxymethyl)aminomethane or other conventional aqueous buffers. The buffer should be present in an amount sufficient to provide a pH within the range of about 5.5 to about 6.5, most preferably 5.9 to 6.1, and performance seems best at a buffer pH of 6.0.
A suitable surfactant can be added in order to enhance wetting with the later used organic materials. It can include conventional natural or synthetic detergents. Suitable results are obtained with sodium lauryl sulfate, for example.
Where sodium lauryl sulfate, the preferred surfactant, is used, it is preferably at a concentration of from 2 to 20 grams per liter, preferably at about 10 grams per liter. For the buffer, if the buffer is malonic acid it is preferably at a concentration of 13 to 26 grams per liter, and preferably at 13 to 14 grams per liter, assuming a pH of 6.0. The buffer may contain tris(hydroxymethyl)amino methane within a range of 12.1 to 25.0 grams per liter, preferably 11.5 to 12.5 grams per liter.
As previously explained, in the preferred embodiment the buffer also contains an enhancer for color. A suitable enhancer is quinoline at a concentration of from 1 to 30 grams per liter, preferably 14 to 15 grams per liter. Also, as an enhancer, one can use isoquinoline-5-sulfonic acid (IQS) at a level of 8 to 30 grams per liter, preferably about 24 grams per liter.
After the bibulous paper matrix is impregnated with the aqueous solution, it is then dried. It may be air-dried or oven-dried. Once the paper is dry, it is then ready for impregnation with organic components which include the preservative, an oxidant and the occult blood indicator.
As should be apparent, the matrix system is more responsive to the organic-based system because of the wetting surfactant, now present in the first dip materials already dried upon the matrix. However, the first and second dips can be reversed, if desired.
Indicators which have a noticeable color change when wetted with cat urine having occult blood include but are not limited to guaiac, benzidine, ortho-tolidine, ortho-dianisidine, or other “leuco-dyes” which turn various shades and intensities of blue in the presence of occult blood, hemoglobin or other peroxidase-containing blood components.
The most preferred are tetramethylbenzidine such as 3,3′,5,5′-tetramethylbenzidine. Where this is employed, it should be at a level of 1 to 15 grams per liter, preferably 1.5 to 2.5 grams per liter. The preferred tetramethylbenzidine derivatives generally should have a formula of:
where X, X′, Y and Y′ and R and R′ are hydrogen or the most preferred alkyl group of up to six carbon atoms and may be the same or different. Preferably the alkyl group contains four or less carbon atoms. Benzidine type compounds such as 3,3′,5,5′, tetramethylbenzidine, o-tolidine, o-dianisidine, N,N,N′,N′, tetramethylbenzidine, and the like may be used. 3,3′,5,5′, tetramethylbenzidine is the preferable compound for use in the present composition.
The organic phase based system may also contain an oxidant which can be cumene hydroperoxide or, for example, diisopropylbenzene dihydroperoxide (DBDH).
Because the color change of occult blood indicators such as tetramethylbenzidine (3,3′,5,5′, tetramethylbenzidine) fade over time, it is desirable that the system have preservatives such as BHT to preclude unwanted color change before exposure to blood/urine mixtures. This will allow the color to last at least for an 8-hour period. This gives the pet owner sufficient time to notice the color change in the kitty litter box. Butylated hydroxytoluene (BHT) can be a suitable preservative.
The level of occult blood indicator, if it is 3,3′5,5′-tetramethylbenzidine, should be from 1 to 15 grams per liter, preferably 1.5 to 2.5 grams per liter. Preferably the organic phase portion of the dip should also contain a dye such as Acid Red 106 at a range of 8 to 15 mg/l, preferably about 11.5 mg/l. This allows the strips to have the preferred pink color.
The test paper now dried from the first step is impregnated with the second strip solution which may contain as a basic organic solvent ethyl acetate. Because of the wetting agent, one can be assured that any cat urine will wet the reagent paper. The amount of time in the second strip solution should be sufficient to saturate it, perhaps five seconds, but generally within range 3 seconds to 60 seconds.
The amount of time in the first strip or paper solution can also be sufficient for saturation of the matrix.
Once the strips or pieces of matrix test paper are dried, for the second dip they are then cut in sizes and shapes (diamond shape is satisfactory), such that they can be homogeneously admixed with the kitty filler in the cat's litter box.
The buffered matrix pieces, now cut, may be sealed in a foil package of conventional construction, and sold. They will have a shelf life in the sealed container of at least several months, even from 12 months to 18 months. After they are opened, they will be admixed by the pet owner with the cat box filler material and placed in the cat's box. If the cat is suffering from FLUTD, the urine will be deposited on the test pieces which will change from their naturally-occurring pink color to a blue, and maintain that color for at least an 8-hour period. As a result, the pet owner is warned of problems that should signal the need for a visit to the veterinarian.
The color change observed on these strips or matrix pieces in tests has been indicated as stable and does not have a tendency to photo-oxidize upon exposure to light since there is a preservative/anti-oxidant system.
Tests reveal that the composition as herein described can detect red blood cells at a level of 100 per microliter.
As can be seen from the above description and described tests, the invention achieves at least all of its stated objectives.
|
Test devices and methods are provided for detection of feline lower urinary tract disease. The test devices comprise a matrix impregnated with a color indicator and a stabilizer wherein the indicator remains stable when exposed to ambient conditions and wherein a positive color response remains stable for a sufficient time for the color response to be observed. The test devices may be provided for use in combination with conventional cat box filler.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is based upon and claims the benefit of priority of the prior Japanese Patent Application No. 2007-224750 filed on Aug. 30, 2007, the entire contents of which-are incorporated herein by reference.
BACKGROUND
[0002] 1. Field
[0003] This art is related to a method of verifying the operation of a circuit using circuit connection information about connection between logic circuits.
[0004] 2. Description of the Related Art
[0005] When designing a semiconductor integrated circuit, a designer designs a circuit and performs logic synthesis in order to verify whether a problematic portion of the circuit operation is present. Recently, some highly advanced semiconductor integrated circuits have included asynchronous circuits that operate with different clocks in the transmission side and the reception side. In such asynchronous circuits, a phenomenon that is specific to asynchronous circuits occurs (e.g., a metastable state). Since this phenomenon may cause a fault, it is important to verify the asynchronous circuits in the design phase. As used herein, the term “metastable state” refers to a state in which an output level of a signal reception register becomes unstable in accordance with the reception timing of a signal reception register driven with a clock different from that of a signal transmission register.
[0006] FIG. 3 of Japanese Patent Application Laid-open No. 2000-11031 describes a method for extracting a cell for which timing verification is needed when designing a semiconductor integrated circuit. More specifically, when a clock of a signal transmission register is different from a clock of a signal reception register, the registers are extracted as cells for which timing verification is needed.
[0007] However, for example, in the existing technology described in Japanese Patent Application Laid-open No. 2000-11031, an effect of transmission and reception timing of a signal propagating in an asynchronous path on transmission and reception timing of a signal propagating in another asynchronous path may not be extracted. Accordingly, if an error is detected during circuit verification (e.g., timing verification), the designer manually needs to determine whether the cell itself is problematic, an asynchronous path between cells is problematic, or signal propagation timing between asynchronous paths is problematic.
SUMMARY OF THE INVENTION
[0008] According to an aspect of an embodiment, a method of verifying a circuit for use in an apparatus for verifying a circuit operation indicated by circuit information, the circuit including a plurality of logic circuits and at least one connection line between the logic circuits, the method includes: obtaining information of a plurality of asynchronous circuits from the circuit information; determining information of asynchronous circuits of a first type and a second type stored in a library; extracting information of an asynchronous circuit of a third type including the asynchronous circuits of the first type and the second type; and extracting verification information associated with the information of the asynchronous circuit of the third type, for verifying the circuit.
[0009] Additional objects and advantages of the invention 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. The object and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.
[0010] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 illustrates an example asynchronous circuit that is an asynchronous verification target;
[0012] FIG. 2 is a flow chart of an asynchronous verification method;
[0013] FIG. 3 is a schematic illustration of a library (a lowermost layer and a middle layer);
[0014] FIG. 4 is a schematic illustration of the library (an upper layer and an uppermost layer);
[0015] FIG. 5 illustrates a correspondence relationship between circuit part information in the library and verification information;
[0016] FIG. 6 is a flow chart from extraction of circuit part information to output of verification information;
[0017] FIG. 7 illustrates the result of abstraction of asynchronous circuit by using lower-layer part information;
[0018] FIG. 8 illustrates an example of an asynchronous circuit in which a combinational circuit is located in an asynchronous connection path;
[0019] FIG. 9 illustrates the result of abstraction of an asynchronous circuit by using middle-layer part information;
[0020] FIG. 10 illustrates an example of assertion information registered with the library;
[0021] FIG. 11 illustrates a relationship between extracted pieces of verification information according to an embodiment of the present technique;
[0022] FIG. 12 illustrates an exemplary hardware configuration of a computer according to an embodiment of the present technique;
[0023] FIG. 13 illustrates a metastable state of an asynchronous circuit;
[0024] FIG. 14 illustrates a problem caused by a metastable state of an asynchronous circuit; and
[0025] FIG. 15 illustrates a timing shift that is likely to occur in an asynchronous circuit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Embodiments will be described below. The present invention is not limited to the following embodiments.
[0027] FIG. 1 illustrates an exemplary asynchronous circuit that is a verification target and that is extracted from a given circuit. In the present embodiment, asynchronous paths are searched for in design information about the asynchronous circuit, and timing information between the asynchronous paths is output as verification information. The present exemplary embodiment is schematically described next with reference to FIG. 1 . Reference numerals 421 to 430 represent registers. As used herein, the term “register” refers to a circuit that outputs an input signal in synchronization with a clock. Reference numerals 431 and 432 represent selectors. Reference numerals 401 to 409 represent circuits to be compared with those in a library described below. Reference numerals 450 to 458 represent connection lines. Signals 460 and 461 are input signals. The signals 460 and 461 are synchronized with a clock signal 462 . A signal 464 Is an output signal. The signal 462 and a signal 463 are asynchronous clock signals having different cycles or different phases. As for registers connected to a transmission end and a reception end of the connection line 450 , the register 421 connected to the transmission end is synchronized with the clock signal 462 . In contrast, the register 426 connected to the reception end is synchronized with the clock signal 463 . In this way, by examining clock information supplied to the registers connected to the transmission and reception ends of the connection line 450 , the connection line 450 having the registers to which different clocks are supplied can be detected as an asynchronous connection line. Similarly, the connection lines 451 and 452 can be detected as asynchronous connection lines.
[0028] In a circuit illustrated in FIG. 1 , the asynchronous connection lines are closely related to each other. For example, a logic circuit 406 connected to a reception end of the asynchronous connection line 451 controls output timing of the signal 464 output from a logic circuit 402 connected to the reception end of the asynchronous connection line 450 . By outputting verification information, such as timing verification conditions, on the basis of a relationship between the asynchronous connection lines, the accuracy of the verification of an asynchronous circuit can be increased.
[0029] FIG. 2 is a flow chart of an asynchronous verification method. The flow from extraction of related asynchronous connection lines to output of verification information between the asynchronous connection lines is described with reference to the flow chart shown in FIG. 2 . These processes are performed by a central processing unit (CPU) 1003 . In logic synthesis step S 101 of FIG. 2 , the CPU 1003 performs logic synthesis on the basis of circuit design information written in a register transfer level (RTL) and outputs circuit connection information including logic circuit information and connection line information. As used herein, the term “RTL” refers to a level in which a circuit is represented by registers, such as flip-flops, and combinational logic circuits. In clock net extraction step S 102 , the CPU 1003 extracts clock information about clocks that drive registers from the circuit connection information. In path extraction step S 103 , the CPU 1003 determines whether a domain crossing exists, that is, whether an connection line for which a transmission register and a reception register have different clock domains exists. If a domain crossing exists, the CPU 1003 , in step S 104 , determines that that connection line is an asynchronous connection line and extracts the connection line. In lowermost layer part extraction step S 105 , the CPU 1003 searches for circuit information that is included in the circuit connection information and that matches lowermost layer part information registered in a library 105 . If matched information is found, the CPU 1003 extracts the circuit information as a lowermost layer part. Here, the library 105 includes circuit part information about parts that form an asynchronous circuit together with style check information and dynamic check information registered therein in a hierarchical structure. The details of the library 105 are described below. In middle/upper layer part information extraction step S 106 , the CPU 1003 searches the library for middle layer part information that matches the circuit information, starting from the asynchronous connection line extracted in step S 104 , using the types of pieces of the lower layer part information, the connection relationship between the pieces of the lower layer part information, and the path information of the clock domain. If matched information is found, the CPU 1003 , in step S 107 , extracts the information as middle layer part information and outputs the information as verification information. As used herein, the term “verification information” refers to information corresponding to circuit part information defined in the library 105 and used for verifying the operation of the circuit. By outputting a signal name written in the circuit connection information processed in step S 101 as the verification information, the designer can easily perform verification. In step S 108 , the CPU 1003 further searches the library 105 for higher layer part information that matches the circuit information using the types of pieces of the middle layer part information and information about signal paths connecting the pieces of the middle layer part information. If matched information is found, the CPU 1003 extracts the information as upper layer part information in step S 107 and outputs the information as verification information in step S 109 . In a similar manner, the CPU 1003 , in step S 108 , searches the library to determine whether a part that matches the circuit information is present in further upper layers. If matched information is found, the CPU 1003 , in step S 107 , outputs the information as part information. In step S 109 , the CPU 1003 outputs verification information. However, if matched information is not found, the part extraction process is completed. Each of the steps is included in more detail below. In this description, verification information is output each time part information is extracted in each layer. However, only verification information for the uppermost layer part information may be output.
[0030] According to this method for verifying a circuit, asynchronous circuit information and verification information between the asynchronous circuit information can be automatically extracted. Thus, the efficiency and the accuracy of verification of a logic circuit including an asynchronous circuit can be improved.
[0031] FIGS. 3 and 4 schematically illustrate circuit part information stored in the library 105 . Circuit part information is registered in the library 105 in a hierarchical structure in accordance with the circuit scale thereof. As the layer becomes higher, the circuit scale of the circuit part information becomes larger. The details of each layer and a relationship between the layers are described next with reference to FIGS. 3 and 4 .
[0032] As shown in FIG. 3 , in a lowermost layer 201 , a logic block including at least one logic circuit is defined as circuit part information. By using the lowermost layer 201 , a minimum logic block of an asynchronous circuit can be extracted. In a middle layer 202 illustrated in FIG. 3 , a combination of an asynchronous connection line and parts defined in the lowermost layer 201 and connected to either end of the asynchronous connection line is defined as circuit part information. By using the middle layer 202 , a minimum component of an asynchronous circuit can be extracted.
[0033] In an upper layer 203 illustrated in FIG. 4 , a combination of parts defined in the layers 201 and 202 , which are below the middle layer, is defined as circuit part information. In an uppermost layer 204 , a combination of parts defined in the layers 201 , 202 , and 203 , which are below the upper layer, is defined as circuit part information. By using the upper layer 203 or the uppermost layer 204 , a plurality of combinations of asynchronous circuits can be extracted.
[0034] It is desirable that a circuit configuration frequently used is registered in the library as circuit part information. Furthermore, in the library, parts having the same function but having different circuit configurations are defined in the same category. For example, in the circuit part information in the lowermost layer 201 illustrated in FIG. 3 , circuit part information 215 and circuit part information 216 are registered in a multiplexer part group 211 a. The circuit part information 215 indicates that an input signal 215 a and a control signal 215 b are input to a selector in synchronization with a clock 215 c of a register, and an output signal 215 d is output. In contrast, the circuit part information 216 indicates that an input signal 216 a and a control signal 216 b are input to a selector in synchronization with a clock that is not synchronized with a clock 216 c of a register, and an output signal 216 d is output. In this way, the pieces of information about circuit parts having the same circuit configuration, but having a register and a selector synchronously operating and having a register and a selector asynchronously operating are registered as parts in the same category. As the number of parts in the same category increases, the probability that a circuit is verified as matching a part in the library can be increased. Similarly, a combinational circuit 212 a includes circuit part information 250 as a part group. A register 213 a includes circuit part information 251 as a part group. A synchronizer 214 a includes circuit part information 252 to 254 as a part group. As used herein, the term “combinational circuit” refers to a circuit including no registers and outputting a signal determined by a combination of a plurality of input logic signals. The term “register” refers to a circuit that outputs an input signal in synchronization with a clock. The term “synchronizer” refers to a circuit having at least one register connected thereto, the registers operating with the same clock in order to synchronize signals with each other.
[0035] In the middle layer 202 illustrated in FIG. 3 , a data transfer asynchronous path 221 a and a control transfer asynchronous path 222 a are defined as circuit part information. In addition, each of circuit part information 255 and 256 is defined as a part group. As used herein, the term “data transfer asynchronous path” refers to a data signal transfer path in which a transmission register and a reception register operate in synchronization with different clocks. The term “control transfer asynchronous path” refers to a control signal transfer path in which a transmission register and a reception register operate in synchronization with different clocks. Each of multiplexers 211 b and 211 c, a register 213 b, and a synchronizer 214 b corresponds to one of the pieces of circuit part information defined in the lowermost layer 201 .
[0036] As shown in FIG. 4 , a control data transfer structure 231 a is defined in the upper layer 203 . A handshake structure 241 is defined in the uppermost layer 204 . The control data transfer structure 231 a includes circuit part information 257 as a part group. The handshake structure 241 includes circuit part information 258 and 259 . As used herein, the term “control data transfer structure” refers to a structure in which the output of the data transfer asynchronous path is controlled using the output of the control transfer asynchronous path. The term “handshake structure” refers to a structure in which a plurality of asynchronous paths are coupled with each other using a combinational circuit. Each of a data transfer asynchronous path 221 b , control transfer asynchronous paths 222 b and 222 c , combinational circuits 212 b to 212 e, registers 213 c to 213 f , and control data transfer structures 231 b to 231 d corresponds to one of the pieces of circuit part information defined in the lowermost layer 201 , the middle layer 202 , and the upper layer 203 below the uppermost layer 204 .
[0037] Note that, in the present embodiment, the number of layers of the library is four. However, the present technique is not limited thereto. For example, the number of layers of a matching logic circuit may be further increased.
[0038] FIG. 5 illustrates a correspondence relationship between circuit part information 301 about each of the parts described in the library 105 shown in FIG. 2 and verification information 302 generated on the basis of the circuit part information 301 . The verification information 302 is generated each time a part is detected. The verification information 302 facilitates verification of each of the parts. In FIG. 5 , all of the verification information 302 relating to a part is included in one table. However, the verification information 302 may be defined using a plurality of tables, such as an element definition table and a connection definition table, each for one piece of part information. Unique identification information 311 and part component information 312 are defined in the circuit part information 301 . Furthermore, a style check item 313 , dynamic check information 314 about a part, and specific information 315 about the part are defined in the circuit part information 301 . The unique identification information 311 includes a name of a category of the part and a unique name of the part. The component 312 of the part includes specific information about the lower layer part information of the part, the lower layer part information, the connection information between parts, clock domain information supplied to the part, and clock net information in the part. These pieces of information are used for extracting a part registered in the library 105 using circuit design information about a verification target.
[0039] The style check item 313 includes style requirements that the part should meet, the severity levels of the requirements, and risk information estimated when the part does not meet the requirements. The dynamic check information 314 about the part includes a timing condition of a change in an input signal that the part expects, assertion information corresponding to an operating condition of the part, and coverage information. As used herein, the term “assertion information” refers to information used for verifying whether a logic circuit is operating as desired. The term “coverage information” refers to information including a range of variations in time to be verified, such as range information about a cycle shift occurring in an asynchronous path due to a phase shift of a clock.
[0040] The signal name of a path connected to the part, the bit width of the signal, and the clock name of the signal are extracted from the circuit design information and are output into the specific information 315 . Furthermore, check items that may not be determined using only the information in the part and, therefore, need to be supported by the upper layer may be defined in the specific information 315 .
[0041] A correspondence relationship between the circuit part information 301 and the verification information 302 is as follows. Circuit information to be searched is selected from a circuit after logic synthesis is performed. Thereafter, the circuit information is compared with the part component information 312 . If circuit part information having the same circuit configuration as that of the searched target is found in the library, the verification information 302 is output on the basis of the circuit part information 301 for the part. The correspondence between the style check item 313 and a style check result 318 is as follows. When the verification information 302 is output, verification is performed on the basis of the style check item 313 . Thereafter, the style check result 318 is output into the verification information 302 . Thus, style checking is performed for each of the parts of the asynchronous circuit, and the results can be managed for each of the parts. In addition, specific information 320 of the part refers to circuit design information to be verified and outputs necessary pieces of information on the basis of the specific information 315 defined in the circuit part information 301 .
[0042] FIG. 6 is a detailed flow chart of a style check process in the processing starting from detection of circuit part information to output of verification information. The flow chart shown in FIG. 6 corresponds to the part extraction step in step S 105 or S 107 of the flow chart shown in FIG. 2 . In step S 200 , the CPU 1003 described in more detail below extracts given circuit information 151 from circuit connection information 150 . In step S 201 , the CPU 1003 searches the library 105 in order to determine whether the same circuit part information is registered in the library 105 . If, in step S 202 , the CPU 1003 determines that the same circuit part information exists, the CPU 1003 , in step S 203 , extracts the specific information 320 from actual circuit information on the basis of the definitions in the circuit part information and generates the verification information 302 . However, if, in step S 202 , the CPU 1003 determines that the same circuit part information does not exist in the library 105 , the CPU 1003 , in step S 204 , extracts other circuit information of circuit connection information. In step S 201 , the CPU 1003 searches the library again. Subsequently, in step S 205 , the CPU 1003 extracts the style check item 313 defined in the circuit part information in the library 105 . In step S 206 , the CPU 1003 performs style checking on the specific information 320 written in the verification information 302 generated in step S 203 . The style check item 313 includes the severity of each of the items. After the style checking is performed in step S 206 , if the part is designed in accordance with the definitions of the library, the CPU 1003 , in step S 207 , outputs a message indicating that information as the style check result 318 . However, if the part is not designed in accordance with the definitions of the library, the CPU 1003 , in step S 207 , outputs a message indicating that information as the style check result 318 together with the severity level of the check item. By outputting the severity level of the check item together with a message, a designer can be informed of the risk level of a design that does not meet the requirements of the check item. In step S 208 , the CPU 1003 determines whether an unprocessed check item is present. If an unprocessed check item is present, the CPU 1003 performs the process in step S 206 again. However, an unprocessed check item is not present, the CPU 1003 completes the processing.
[0043] An example of processing of the flow chart shown in FIG. 6 is described next with reference to the circuit information 401 shown in FIG. 1 . The circuit information 401 includes the selector 431 and the register 421 . A part indicated by the circuit part information having the same configuration is defined in the lowermost layer 201 shown in FIG. 3 as the multiplexer 215 . Accordingly, the CPU 1003 assigns a part name “DMUX” to the circuit information 401 and outputs the verification information 302 on the basis of the circuit part information. As shown in FIG. 5 , information items of the verification information 302 to be output are defined for each of pieces of the circuit part information. Therefore, the specific information 320 extracted from the actual circuit on the basis of the circuit part information 301 is output as the verification information 302 . The above-described processing for outputting the verification information 302 is performed by verification information extracting means 1003 c shown in FIG. 12 described below. For example, the following information items are output as verification information items of the extracted circuit information 401 :
[0044] part type category: multiplexer
[0045] part name: DMUX
[0046] register clock: clock 462
[0047] select input signal: connection-line- 453 propagation signal
[0048] select signal bit width: 1
[0049] select signal synchronization clock: clock 462
[0050] data input signal: signal 460
[0051] data input signal bit width: 32
[0052] data input signal synchronization clock: clock 462
[0053] data output signal: connection-line- 450 propagation signal
[0054] data output signal bit width: 32
[0055] data output signal synchronization clock: clock 462
[0056] Furthermore, when outputting the verification information, the CPU 1003 extracts the style check item 313 of the circuit part information 215 shown in FIG. 3 and performs style checking on the basis of the actual circuit information 401 . The CPU 1003 then outputs the style check result 318 as the verification information 302 . For example, if the style check item 313 of the circuit part information 215 defined in the library indicates that a data input signal is synchronized with a clock of a register, the CPU 1003 compares a clock supplied to a register that generates the data input signal with a clock supplied to a register of the circuit information to be verified. If the two clocks are the same, the CPU 1003 writes the result into the verification information 302 as the style check result 318 . Furthermore, the CPU 1003 outputs, into the verification information 302 , information indicating that the circuit information 401 has passed the verification.
[0057] In addition, the CPU 1003 verifies the circuit information (the logic circuit) 402 and detects that the data input signal is synchronized with the clock signal 462 and that the register 426 is synchronized with the clock signal 463 . Accordingly, the CPU 1003 outputs information indicating that the clock of the logic circuit 402 is different from the clock of the circuit information 401 as the style check result 318 and the verification information 302 . Furthermore, the CPU 1003 outputs, as the verification information 302 , information indicating that the severity level in the verification result is a level that requires designer's confirmation. In this way, the designer easily monitors the verification result of the logic circuit of the asynchronous circuit, and therefore, the efficiency of verification can be improved.
[0058] The logic indicated by the circuit part information (the multiplexer group) 211 a is that a data input signal is output in synchronization with a register clock only for a period of time in which an input signal to a selector is effective. For example, if information indicating that a data input signal is not changed for a period of time in which a select input signal is effective is defined in the circuit part information (a multiplexer) 211 a as a dynamic check item of the circuit information, that information is written in the verification information as dynamic check information of the asynchronous circuit.
[0059] The circuit information (the logic circuit) 406 includes two registers: a register 427 and a register 428 . The asynchronous connection line (an input signal) 451 of the register 427 is output from a register 423 . The operating clocks of the register 423 and the register 427 are different. Accordingly, the circuit information 406 is extracted as lowermost-layer circuit part information 214 in the library shown in FIG. 3 . As in the case of the circuit information 401 , the verification information 302 is output. For example, the following items are output as the verification information of the circuit information 401 :
[0060] part type category: synchronizer
[0061] part name: 2-DFF
[0062] register clock: clock 463
[0063] input signal: connection-line- 451 propagation signal
[0064] input signal bit width: 1
[0065] input signal synchronization clock: clock 462
[0066] output signal: connection-line- 454 propagation signal
[0067] output signal bit width: 1
[0068] output signal synchronization clock: clock 462
[0069] In addition, by registering information indicating that a combinational circuit is not present between two registers and that an connection line between the two registers has no branch as a style check item of the circuit part information (the synchronizer) 214 a , the CPU 1003 can output the verification result into the verification information as a style check result. In addition, in order for the circuit information 406 to operate as a synchronizer, a signal input from the asynchronous connection line 451 needs to be effective for at least two successive cycles of the clock signal 463 . Accordingly, the CPU 1003 acquires the assertion information from the circuit part information (synchronizer) 214 a and outputs the assertion information into the verification information. In this way, the CPU 1003 can perform logic verification for the circuit information 406 . Furthermore, two or three cycles of variance range are present between a signal propagating in the asynchronous connection line 451 of the circuit information 406 and a signal propagating in an connection line 454 due to metastability. Such information is also acquired from the circuit part information 214 a and is output as dynamic check information of the circuit information 406 .
[0070] Subsequently, extraction of circuit information 403 is described next. The circuit information 403 does not include a register. Such a part is extracted as a combinational logic on the basis of the circuit part information (combinational circuit) 212 a , and the following verification information items are output:
[0071] input signal 1 : signal 461
[0072] synchronization clock of the input signal 1 : clock
[0073] input signal 2 : connection-line- 456 propagation signal
[0074] synchronization clock of the input signal 2 : clock
[0075] In addition, the state of generating an output signal is output as verification information on the basis of the circuit part information 212 a . Similarly, verification information is output for other parts.
[0076] As described above, by outputting the style verification result and dynamic verification information for each of the pieces of circuit information into the verification information, the efficiency of a style check operation for each of the pieces of circuit information can be improved. In addition, the efficiency of verification of the asynchronous circuit can be improved, since conditions for verifying the logic and operation of the entire asynchronous circuit can be defined.
[0077] FIG. 7 illustrates the result of abstraction of the asynchronous circuit shown in FIG. 1 by referring to the lowermost layer library. Pieces of verification information 501 to 509 abstracted on the basis of the lowermost layer part information of the library are shown in FIG. 7 . Detection of the middle layer part information is performed by searching the middle layer of the library for part information that is the same as the circuit information, starting from the asynchronous path, in accordance with the flow shown in FIG. 6 using the type of lowermost layer part information, a path between the pieces of lowermost layer part information, and path information about a clock domain (S 201 ). The CPU 1003 compares each of the circuits shown in FIG. 7 with a part in the middle layer part information 202 in the library shown in FIG. 3 so as to detect an area (circuit information) 511 as the circuit part information 221 a . The CPU 1003 assigns a name “DATA_Async_Path” to the area and outputs verification information. The CPU 1003 stores information acquired from the circuit part information 221 a as verification information. In addition, the CPU 1003 outputs the coupling relationship between circuit information 501 and 502 of the circuit information 511 as verification information. The process of outputting the verification information is similar to that for the circuit information 401 . For example, the following information items are output as the extracted verification information relating to the circuit information 511 :
[0078] part type category: data transfer asynchronous path
[0079] part name: DATA_Async_Path
[0080] input data signal: signal 460
[0081] input data bit width: 32
[0082] input data synchronization clock: clock 462
[0083] input control signal: connection-line- 453 propagation signal
[0084] input control signal bit width: 1
[0085] input control signal synchronization clock: clock 462
[0086] output data signal: signal 464
[0087] output data bit width: 32
[0088] output data synchronization clock: clock 463
[0089] output control signal: connection-line- 454 propagation signal
[0090] output control signal bit width: 1
[0091] output control signal synchronization clock: clock
[0092] transmission circuit information: 501
[0093] reception circuit information: 502
[0094] asynchronous connection line: 450
[0095] Furthermore, the CPU 1003 outputs the result of verification performed in accordance with the style check items in the circuit part information 221 a registered in the library as verification information. Suppose that one of the style check items of the circuit part information 221 a defines that, for example, a combinational circuit is not used in a signal connection line. Although each of the transmission circuit information 501 and reception circuit information 502 includes a register, the combinational circuit includes no registers. Accordingly, if an connection line between logic circuits having registers includes, in the middle thereof, a logic circuit having no registers, the CPU 1003 determines that the logic circuit is a combinational circuit. In the present embodiment, since a combinational circuit is not present, that result is output into verification information.
[0096] FIG. 8 illustrates an example of a circuit in which a combinational circuit is present in an asynchronous connection line. A combinational circuit 601 is located in a route between asynchronous connection lines 451 a and 451 b . The combinational circuit 601 is controlled by a control signal 465 synchronized with the clock signal 462 . An output operation of verification information performed when a combinational circuit is present in an asynchronous connection line is described below with reference to FIG. 8 . As shown in FIG. 8 , when the combinational circuit 601 is located in a route between asynchronous connection lines 451 a and 451 b , the CPU 1003 outputs that information as a style check result together with the severity. Even when the combinational circuit 601 is present, the circuit operates without any problem if a change in the control signal 465 does not occur during a data transfer sequence of an connection-line- 451 a propagation signal. Accordingly, the severity level of the output verification information can be set to a low value. In this way, information indicating that no circuit design mistakes are found, but a combinational circuit is present can be output as verification information in order to give a warning to the designer. Thus, the efficiency of verification can be improved.
[0097] Referring back to FIG. 7 , suppose that, as dynamic check information about the circuit part information 221 a , information indicating that a select signal of the reception circuit part information 211 c is a select signal of the transmission circuit part information 211 b delivered using an asynchronous control transfer part is registered in the library. In this case, that information is output as verification information of this part. This verification information is not used in the layer of this layer. However, this information is useful when, in the upper layer, the connection relationship between the part and asynchronous control transfer circuit information (an area) 512 becomes clear. Accordingly, the CPU 1003 outputs this information into verification information as specific information. The area 512 and an area 513 are extracted in the same manner.
[0098] FIG. 9 illustrates the result of abstraction of the asynchronous circuit shown in FIG. 7 by referring to the middle layer circuit part information shown in FIG. 3 . In FIG. 9 , pieces of verification information (part information) 701 to 703 are extracted on the basis of the middle layer part information of the library. Detection of the upper layer part information 203 is performed by searching for the upper layer part information 203 that matches part information in accordance with the flow shown in FIG. 2 using the type of part information, connection lines connecting parts, and clock domain information in the layers below the middle layer. The CPU 1003 examines a connection relationship between the part information 701 and the part information 702 using parameters written in the verification information. Thus, the CPU 1003 recognizes that an input control signal of the part information 701 is an input signal of the part information 702 and that an output control signal of the part information 701 is an output signal of the part information 702 . In addition, since the part information 701 is asynchronous data transfer part information and the part information 702 is asynchronous control transfer part information, the CPU 1003 compares each of the part information 701 and 702 with the upper layer part information in the library shown in FIG. 4 so as to determine circuit part information that matches the circuit information shown in an area (circuit information) 711 is the circuit part information (control data transfer structure) 231 a that is present in the upper layer of the library. The CPU 1003 assigns a name “DATA_Ctrl_Async_Path” to the detected area 711 . After the corresponding circuit part information is detected in the library, the CPU 1003 outputs the verification information 302 corresponding to the description in circuit part information 231 on the basis of FIG. 5 . Information acquired from the circuit part information 231 is stored in the verification information. Output processing of the verification information is similar to that for the circuit information 401 . For example, the following items are stored as detected verification information about the circuit information 711 :
[0099] part type category: control data transfer structure
[0100] part name: DATA_Ctrl_Async_Path
[0101] input data signal name: signal 460
[0102] input data signal bit width: 32
[0103] input data signal synchronization clock: clock 462
[0104] input control signal name: connection
[0105] line- 453 propagation signal
[0106] input control signal bit width: 1
[0107] input control signal synchronization clock: clock 462
[0108] output data signal name: signal 464
[0109] output data signal bit width: 32
[0110] output data signal synchronization clock: clock 463
[0111] output control signal name: connection-line- 454 propagation signal
[0112] output control signal bit width: 1
[0113] output control signal synchronization clock: clock 463
[0114] lower layer part information (data) 1 : 701
[0115] lower layer part information (control) 1 : 702
[0116] After circuit part information in the upper layer is detected, the CPU 1003 verifies the items that are not able to be verified in the lower layers. For example, a connection relationship relating to the select signal of the circuit information 511 may not be verified in the middle layer shown in FIG. 7 . However, it can be determined that an connection line 454 is connected to a part indicated by the part information 702 in the upper layer shown in FIG. 9 . Accordingly, the CPU 1003 outputs this information as verification information.
[0117] In addition, the asynchronous connection lines 450 and 451 of the circuit information 711 have the same signal propagation direction. Signals propagating in the connection lines 450 and 451 are output in synchronization with the clock signal 462 with a shift of zero cycle. When these signals are asynchronously transferred to the clock signal 463 , a cycle shift may occur. This variance range is generated as a cycle difference of the clock signal 463 starting from a change point of a signal propagating in the connection line 450 observed from a side of the clock signal 463 to when a signal propagating in the connection line 454 is effective. Such information is registered in the circuit part information. Upon outputting the verification information, the CPU 1003 refers to circuit part information 231 a in the library and outputs the data into the verification information as coverage information, which is dynamic check information of circuit part information.
[0118] The search in further upper layers continues until no more upper layers are present. In FIG. 9 , a signal propagating in the connection line 454 synchronized with the clock signal 463 output from the part information 702 is used for generating a signal propagating in an connection line 455 via the register 509 . In addition, using the circuit information 703 , this signal is subjected to asynchronous crossing to the asynchronous connection line 452 synchronized with the clock signal 462 . A signal propagating in an connection line 456 is used for generating a signal propagating in an connection line 453 via circuit information 704 and 705 . Since this structure is a structure in which a control signal travels back and force in an asynchronous path using circuit information for a control signal, the CPU 1003 can determine that circuit information 712 has a structure the same as the handshake structure 241 in the uppermost layer. The output processing of the verification information is performed in a similar manner to that for the circuit information 401 . For example, the following items are stored as detected verification information about the circuit information 712 :
[0119] part type category: handshake structure
[0120] part name: DATA_HandShake_Part
[0121] input data signal name: signal 460
[0122] input data signal bit width: 32
[0123] input data signal synchronization clock: clock 462
[0124] input control signal name: signal 461
[0125] input control signal bit width: 1
[0126] input control signal synchronization clock: clock 462
[0127] output data signal name: signal 464
[0128] output data signal bit width: 32
[0129] output data signal synchronization clock: clock 463
[0130] lower layer circuit information (forward path) 1 : 711
[0131] lower layer circuit information (return path) 1 : 703
[0132] If an asynchronous circuit structure is identified, the operational requirements that the asynchronous circuit structure should meet are determined. By outputting assertion information with which the operation is monitored as verification information on the basis of the circuit part information registered in the library, it can be determined whether an input for which the asynchronous circuit structure may not assure the operation in asynchronous verification, such as logic verification simulation, is received from nearby synchronous circuits. As used herein, the term “assertion information” refers to definitions of conditions that should be established between an input signal and an output signal of a logic circuit. Examples of a language for defining assertion information include PSL (Property Specification Language) and SVA (System Verilog Assertion).
[0133] FIG. 10 illustrates an example of assertion information about the circuit information 712 written using PSL, which is an assertion language. In FIG. 10 , a signal STB_CDC propagates in the asynchronous connection line 451 , and a signal RDY_CDC propagates in the connection line 452 . In FIG. 10 , assertion information about signals other than the signals STB_CDC and RDY_CDC is defined when the signals propagating in the asynchronous connection lines 451 and 452 are effective. A signal STB_SYNC propagates in the connection line 454 , and a signal RDY_PRE propagates in the connection line 455 . By registering such descriptions in the library, the CPU 1003 can detect corresponding asynchronous circuit part information and output the detected asynchronous circuit part information into the verification information as dynamic check information of the circuit part information. In this way, assertion information appropriate for the asynchronous circuit structure can be provided, and therefore, verification of an asynchronous circuit can be efficiently performed.
[0134] The circuit part information (handshake structure) 241 shown in FIG. 4 is a minimum unit of an asynchronous logic structure having the asynchronous operation thereof that does not affect other logic circuits. By registering information indicating that the asynchronous circuit is a minimum unit as circuit information of the circuit part information 241 , the CPU 1003 can output such information as verification information. In this way, a designer can clarify the verification range of the asynchronous circuit, and therefore, the verification efficiency of a circuit can be increased.
[0135] FIG. 11 illustrates a connection relationship between verification information in the layers extracted according to the present embodiment. In FIG. 11 , verification information 910 to 922 located in a lowermost layer 901 , a middle layer 902 , an upper layer 903 , and the uppermost layer 904 include their own pointers, that is, addresses corresponding to the verification information. The string “Cat.” written in these pieces of verification information indicates a part type category. The string “Name” indicates a part name. Lines between these pieces of verification information indicate an address reference relationship. For example, by adding address information (pointers) about the lowermost layer part information (the verification information) 910 and 911 to a part component of the middle layer part information 918 , a coupling relationship between the verification information can be clarified. As described above, by defining a coupling relationship between the verification information in the upper and lower layers in addition to circuit part information in each layer, a designer can recognize a whole structure of the asynchronous circuit, and therefore, verification of the asynchronous circuit can be efficiently performed.
[0136] FIG. 12 illustrates an exemplary hardware configuration of a computer. A computer includes a display unit 1001 , input means 1002 , the CPU 1003 , a random access memory (RAM) 1004 , an image processing unit 1005 , and a storage unit 1007 . These components are connected with each other via a bus 1006 . In addition, an asynchronous verification program 1008 , a library 1009 , verification information 1010 , and circuit connection information 1011 to be verified are stored in the storage unit 1007 .
[0137] By executing the asynchronous verification program 1008 on the computer having such a hardware configuration, circuit connection line detecting means 1003 a , part information detecting means 1003 b , and verification information extracting means 1003 c are generated by the CPU 1003 . The circuit connection line detecting means 1003 a executes the process in step S 104 shown in FIG. 2 . The part information detecting means 1003 b and the verification information extracting means 1003 c execute the processes in steps S 105 and S 107 shown in FIG. 2 .
[0138] The asynchronous verification program 1008 that describes the details of processing can be recorded in a computer-readable recording medium. Examples of the computer-readable recording medium include a magnetic recording unit, an optical disk, and a semiconductor memory.
[0139] In order to distribute the program, for example, removable recording media, such as digital versatile discs (DVDs) and compact disk-read only memories (CD-ROMs), for storing the program are used. Alternatively, the program may be stored in a storage unit of a server computer, and the server computer may transfer the program to other computers.
[0140] As described above, according to the present technique, the asynchronous circuit verification method and the asynchronous circuit verification program can detect an asynchronous circuit and abstract the asynchronous circuit as a part by referring the library in a style check phase after logic synthesis is performed. Subsequently, style check items and dynamic check information for each part are output as verification information. As a result, verification of the operation between asynchronous paths can be performed, and therefore, the efficiency of verification of an asynchronous circuit and the accuracy of verification can be improved.
[0141] FIG. 13 illustrates the occurrence of an unstable period of an output signal due to metastability of an asynchronous path. Reference numerals 1101 to 1103 represent registers. Reference numerals 1151 a to 1153 a represent signals propagating between the registers. Reference numerals 1154 a to 1155 a represent asynchronous clocks having different cycles and phases. Reference numeral 1154 b represents the waveform of the clock 1154 a , reference numeral 1151 b represents the waveform of the signal 1151 a , reference numeral 1155 b represents the waveform of the clock 1155 a , reference numeral 1152 b represents the waveform of the signal 1152 a , and reference numerals 1153 b and 1153 c represent the waveforms that possibly occur in the signal 1153 a. As shown by the waveform diagram in FIG. 13 , when the rises of the waveforms 1154 b and 1155 b occur at substantially the same timing point, the output signal 1152 a of the register 1102 becomes unstable, as shown by the waveform 1152 b . In this case, the timing of the output signal 1153 a from the register 1103 may be represented by the waveform 1153 b or 1153 c depending on whether the register 1103 determines that the output signal 1152 a from the register 1102 has a high level at a time T 1 or T 2 .
[0142] FIG. 14 illustrates the case where such an asynchronous path causes a problem. Reference numerals 1201 to 1204 represent registers. Reference numeral 1205 represents an AND circuit. Reference numerals 1250 a to 1253 a represent the output signals of the registers 1201 to 1204 , respectively. Reference numerals 1270 and 1271 represent asynchronous circuits. Clocks 1254 a and 1255 a are asynchronous clocks having different cycles and phases. Reference numeral 1256 a represents the output signal of the AND circuit 1205 . A waveform 1254 b represents the clock 1254 a . A waveform 1250 b represents the signal 1250 a. A waveform 1251 b represents the signal 1251 a . A waveform 1255 b represents the clock 1255 a . A waveform 1252 b represents the signal 1252 a . A waveform 1253 b represents the signal 1253 a. As a result of metastability, the phase of the output signal 1252 a from the register 1202 is shifted from the phase of the output signal 1253 a from the register 1204 , as in the case of the waveform 1252 b and the waveform 1253 b . At that time, a pulse 1263 is unintentionally output in a waveform 1256 b of an output signal of the AND circuit 1205 . The unintended pulse 1263 may cause a circuit to operate incorrectly. If a coupling relationship between asynchronous circuits is unknown, performance of verification is required under the assumption that one asynchronous circuit is related to all of the other asynchronous circuits. This requirement increases the verification time of an asynchronous circuit and decreases the accuracy of the verification.
[0143] The present embodiment is applied to circuits shown in FIG. 14 . Verification information about asynchronous circuits 1270 and 1271 shown in FIG. 14 is output by referring to the circuit part information thereof. Furthermore, circuit part information in the upper layer is referenced. If matched circuit part information is registered in the library, a relationship between the two asynchronous circuits 1270 and 1271 is output as verification information. More specifically, signals 1250 and 1251 are transferred to the registers 1202 and 1204 operating with a clock 1255 a so as to become signals 1252 a and 1253 a. Accordingly, the CPU 1003 generates, as verification information, coverage information indicating that a period difference between the signals 1252 a and 1253 a may be one of the following three values: −1, 0, and +1 when the clock 1255 a is input.
[0144] FIG. 15 illustrates the above-described three period differences using time-varying waveforms. A time-varying waveform 1301 represents a waveform when the signal 1253 a is behind the signal 1252 a by one cycle. A time-varying waveform 1302 represents a waveform when the signals 1252 a and 1253 a have the same timing. A time-varying waveform represents a waveform when the signal 1253 a is ahead of the signal 1252 a by one cycle.
[0145] As described above, by using verification information including signal propagation timing requirements between asynchronous paths for timing verification, the efficiency and the accuracy of verification of a logic circuit including an asynchronous circuit can be improved.
|
A method of verifying a circuit for use in an apparatus for verifying a circuit operation indicated by circuit information, the circuit including a plurality of logic circuits and at least one connection line between the logic circuits, the method includes: obtaining information of a plurality of pieces of asynchronous circuits from the circuit information; determining information of asynchronous circuits of a first type and a second type stored in a library; extracting information of an asynchronous circuit of a third type including the asynchronous circuits of the first type and the second type; and extracting verification information associated with the information of the asynchronous circuit of the third type, for verifying the circuit.
| 6
|
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a 35 USC §371 National Stage application of PCT Application No. PCT/US2004/019453 filed Jun. 18, 2004; which is a continuation application of U.S. application Ser. No. 10/838,157 filed Apr. 30, 2004, now pending; which is a continuation-in-part application of U.S. application Ser. No. 10/600,854 filed Jun. 20, 2003. The disclosure of each of the prior applications is considered part of and is incorporated by reference in the disclosure of this application.
GRANT INFORMATION
This invention was made with government support under Grant No. CA44848 awarded by the National Institutes of Health, National Cancer Institute. The government has certain rights in the invention.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to anti-neoplastic agents, and more particularly to salinosporamides and their use as anti-neoplastic agents.
2. Background Information
Neoplastic diseases, characterized by the proliferation of cells not subject to the normal control of cell growth, are a major cause of death in humans. Clinical experience in chemotherapy has demonstrated that new and more effective cytotoxic drugs are desirable to treat these diseases. Indeed, the use of anti-neoplastic agents has increased due to the identification of new neoplasms and cancer cell types with metastases to different areas, and due to the effectiveness of antineoplastic treatment protocols as a primary and adjunctive medical treatment for cancer.
Since anti-neoplastic agents are cytotoxic (poisonous to cells) they not only interfere with the growth of tumor cells, but those of normal cells. Anti-neoplastic agents have more of an effect on tumor cells than normal cells because of their rapid growth. Thus, normal tissue cells that are affected by anti-neoplastic agents are rapidly dividing cells, such as bone marrow (seen in low blood counts), hair follicles (seen by way of hair loss) and the GI mucosal epithelium (accounting for nausea, vomiting, loss of appetite, diarrhea). In general, anti-neoplastic agents have the lowest therapeutic indices of any class of drugs used in humans and hence produce significant and potentially life-threatening toxicities. Certain commonly-used anti-neoplastic agents have unique and acute toxicities for specific tissues. For example, the vinca alkaloids possess significant toxicity for nervous tissues, while adriamycin has specific toxicity for heart tissue and bleomycin has for lung tissue.
Thus, there is a continuing need for anti-neoplastic agents that are effective in inhibiting the proliferation of hyperproliferative cells while also exhibiting IC 50 values lower than those values found for current anti-neoplastic agents, thereby resulting in marked decrease in potentially serious side effects.
SUMMARY OF THE INVENTION
The present invention is based on the discovery that certain fermentation products of the marine actinomycete strains CNB392 and CNB476 are effective inhibitors of hyperproliferative mammalian cells. The CNB392 and CNB476 strains lie within the family Micromonosporaceae, and the generic epithet Salinospora has been proposed for this obligate marine group. The reaction products produced by this strain are classified as salinosporamides, and are particularly advantageous in treating neoplastic disorders due to their low molecular weight, low IC 50 values, high pharmaceutical potency, and selectivity for cancer cells over fungi.
In one embodiment of the invention, there is provided compounds having the structure (I):
wherein:
R 1 to R 3 are each independently —H, alkyl, substituted alkyl, alkenyl, substituted alkenyl, alkynyl, substituted alkynyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, heterocyclic, substituted heterocyclic, cycloalkyl, substituted cycloalkyl, alkoxy, substituted alkoxy, thioalkyl, substituted thioalkyl, hydroxy, halogen, amino, amido, carboxyl, —C(O)H, acyl, oxyacyl, carbamate, sulfonyl, sulfonamide, or sulfuryl;
Each R 4 is independently alkyl, substituted alkyl, alkenyl, substituted alkenyl, alkynyl, substituted alkynyl, aryl, substituted aryl, cycloalkyl, substituted cycloalkyl;
E 1 to E 4 are each independently —O, —NR 5 , or —S, wherein R 5 is —H or C 1 -C 6 alkyl; and
x is 0 to 8.
In a further embodiment of the invention, there are provided compounds having the structure (II):
wherein:
R 1 to R 3 are each independently —H, alkyl, substituted alkyl, alkenyl, substituted alkenyl, alkynyl, substituted alkynyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, heterocyclic, substituted heterocyclic, cycloalkyl, substituted cycloalkyl, alkoxy, substituted alkoxy, thioalkyl, substituted thioalkyl, hydroxy, halogen, amino, amido, carboxyl, —C(O)H, acyl, oxyacyl, carbamate, sulfonyl, sulfonamide, or sulfuryl; Each R 4 is independently alkyl, substituted alkyl, alkenyl, substituted alkenyl, alkynyl, substituted alkynyl, aryl, substituted aryl, cycloalkyl, substituted cycloalkyl; E 1 to E 4 are each independently —O, —NR 5 , or —S, wherein R 5 is —H or C 1 -C 6 alkyl; and x is 0 to 8.
In another embodiment of the invention, there are provided compounds having the structure (III):
wherein:
R 1 to R 3 are each independently —H, alkyl, substituted alkyl, alkenyl, substituted alkenyl, alkynyl, substituted alkynyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, heterocyclic, substituted heterocyclic, cycloalkyl, substituted cycloalkyl, alkoxy, substituted alkoxy, thioalkyl, substituted thioalkyl, hydroxy, halogen, amino, amido, carboxyl, —C(O)H, acyl, oxyacyl, carbamate, sulfonyl, sulfonamide, or sulfuryl, each R 4 is independently alkyl, substituted alkyl, alkenyl, substituted alkenyl, alkynyl, substituted alkynyl, aryl, substituted aryl, cycloalkyl, substituted cycloalkyl, E 1 to E 4 are each independently —O, —NR 5 , or —S, wherein R 5 is —H or C 1 -C 6 alkyl, and x is 0 to 8.
In still a further embodiment of the invention, there are provided compounds having the structure (IV):
In a further embodiment of the invention, there are provided compounds having the structure (V):
In a further embodiment of the invention, there are provided compounds having the structure (VI):
In another embodiment, there are provided pharmaceutical compositions including at least one compound of structures I-VI in a pharmaceutically acceptable carrier therefor.
In another embodiment, there are provided articles of manufacture including packaging material and a pharmaceutical composition contained within the packaging material, wherein the packaging material includes a label which indicates that the pharmaceutical composition can be used for treatment of cell proliferative disorders and wherein the pharmaceutical composition includes at least one compound of structures I-VI.
In yet another embodiment, there are provided methods for treating a mammalian cell proliferative disorder. Such a method can be performed for example, by administering to a subject in need thereof a therapeutically effective amount of a compound having structures I-VI.
In an additional embodiment, there are provided methods for producing a compound of structures I-VI having the ability to inhibit the proliferation of hyperproliferative mammalian cells. Such a method can be performed, for example, by cultivating a culture of a Salinospora sp. strains CNB392 (ATCC # —————— ) or CNB476 (ATCC PTA-5275) and isolating from the culture at least one compound of structure I.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts the chemical structure of an exemplary compound of the invention, Salinosporamide A, with relative stereochemistry.
FIG. 2 depicts a phylogenetic tree illustrating the phylogeny of “ Salinospora”.
FIG. 3 depicts the chemical structure of Etoposide, an anti-neoplastic agent in therapy against several human cancers.
FIG. 4 compares the cytotoxic activity and dose response curves of Salinosporamide A and Etoposide.
FIG. 5 is a block diagram depicting an exemplary separation scheme used to isolate Salinosporamide A.
FIGS. 6-14 set forth NMR, IR, and UV spectroscopic data used to elucidate the structure of Salinosporamide A.
FIG. 15 sets forth the signature nucleotides that strains CNB392 and CNB476 possess within their 16S rDNA, which separate these strains phylogenetically from all other family members of the family Micromonosporaceae.
FIG. 16 depicts the chemical structure of an exemplary compound of the invention, salinosporamide A (structure V), with absolute stereochemistry.
FIG. 17 ORTEP plot of the final X-ray structure of salinosporamide A, depicting the absolute stereochemistry.
DETAILED DESCRIPTION OF THE INVENTION
In one embodiment, there are provided compounds having the structure (I):
wherein:
R 1 to R 3 are each independently —H, alkyl, substituted alkyl, alkenyl, substituted alkenyl, alkynyl, substituted alkynyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, heterocyclic, substituted heterocyclic, cycloalkyl, substituted cycloalkyl, alkoxy, substituted alkoxy, thioalkyl, substituted thioalkyl, hydroxy, halogen, amino, amido, carboxyl, —C(O)H, acyl, oxyacyl, carbamate, sulfonyl, sulfonamide, or sulfuryl; Each R 4 is independently alkyl, substituted alkyl, alkenyl, substituted alkenyl, alkynyl, substituted alkynyl, aryl, substituted aryl, cycloalkyl, substituted cycloalkyl; E 1 to E 4 are each independently —O, —NR 5 , or —S, wherein R 5 is —H or C 1 -C 6 alkyl; and x is 0 to 8.
In a further embodiment of the invention, there are provided compounds having the structure (II):
wherein:
R 1 to R 3 are each independently —H, alkyl, substituted alkyl, alkenyl, substituted alkenyl, alkynyl, substituted alkynyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, heterocyclic, substituted heterocyclic, cycloalkyl, substituted cycloalkyl, alkoxy, substituted alkoxy, thioalkyl, substituted thioalkyl, hydroxy, halogen, amino, amido, carboxyl, —C(O)H, acyl, oxyacyl, carbamate, sulfonyl, sulfonamide, or sulfuryl; Each R 4 is independently alkyl, substituted alkyl, alkenyl, substituted alkenyl, alkynyl, substituted alkynyl, aryl, substituted aryl, cycloalkyl, substituted cycloalkyl; E 1 to E 4 are each independently —O, —NR 5 , or —S, wherein R 5 is —H or C 1 -C 6 alkyl; and x is 0 to 8.
In one embodiment, there are provided compounds having the structure (III):
wherein:
R 1 to R 3 are each independently —H, alkyl, substituted alkyl, alkenyl, substituted alkenyl, alkynyl, substituted alkynyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, heterocyclic, substituted heterocyclic, cycloalkyl, substituted cycloalkyl, alkoxy, substituted alkoxy, thioalkyl, substituted thioalkyl, hydroxy, halogen, amino, amido, carboxyl, —C(O)H, acyl, oxyacyl, carbamate, sulfonyl, sulfonamide, or sulfuryl, each R 4 is independently alkyl, substituted alkyl, alkenyl, substituted alkenyl, alkynyl, substituted alkynyl, aryl, substituted aryl, cycloalkyl, substituted cycloalkyl, E 1 to E 4 are each independently —O, —NR 5 , or —S, wherein R 5 is —H or C 1 -C 6 alkyl, and x is 0 to 8.
In still a further embodiment of the invention, there are provided compounds having the structure (IV):
In a further embodiment of the invention, there are provided compounds having the structure (V):
In a further embodiment of the invention, there are provided compounds having the structure (VI):
As used herein, the term “alkyl” refers to a monovalent straight or branched chain hydrocarbon group having from one to about 12 carbon atoms, including methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, tert-butyl, n-hexyl, and the like.
As used herein, “substituted alkyl” refers to alkyl groups further bearing one or more substituents selected from hydroxy, alkoxy, mercapto, cycloalkyl, substituted cycloalkyl, heterocyclic, substituted heterocyclic, aryl, substituted aryl, heteroaryl, substituted heteroaryl, aryloxy, substituted aryloxy, halogen, cyano, nitro, amino, amido, —C(O)H, acyl, oxyacyl, carboxyl, sulfonyl, sulfonamide, sulfuryl, and the like.
As used herein, “lower alkyl” refers to alkyl groups having from 1 to about 6 carbon atoms.
As used herein, “alkenyl” refers to straight or branched chain hydrocarbyl groups having one or more carbon-carbon double bonds, and having in the range of about 2 up to 12 carbon atoms, and “substituted alkenyl” refers to alkenyl groups further bearing one or more substituents as set forth above.
As used herein, “alkynyl” refers to straight or branched chain hydrocarbyl groups having at least one carbon-carbon triple bond, and having in the range of about 2 up to 12 carbon atoms, and “substituted alkynyl” refers to alkynyl groups further bearing one or more substituents as set forth above.
As used herein, “aryl” refers to aromatic groups having in the range of 6 up to 14 carbon atoms and “substituted aryl” refers to aryl groups further bearing one or more substituents as set forth above.
As used herein, “heteroaryl” refers to aromatic rings containing one or more heteroatoms (e.g., N, O, S, or the like) as part of the ring structure, and having in the range of 3 up to 14 carbon atoms and “substituted heteroaryl” refers to heteroaryl groups further bearing one or more substituents as set forth above.
As used herein, “alkoxy” refers to the moiety —O-alkyl-, wherein alkyl is as defined above, and “substituted alkoxy” refers to alkoxyl groups further bearing one or more substituents as set forth above.
As used herein, “thioalkyl” refers to the moiety —S-alkyl-, wherein alkyl is as defined above, and “substituted thioalkyl” refers to thioalkyl groups further bearing one or more substituents as set forth above.
As used herein, “cycloalkyl” refers to ring-containing alkyl groups containing in the range of about 3 up to 8 carbon atoms, and “substituted cycloalkyl” refers to cycloalkyl groups further bearing one or more substituents as set forth above.
As used herein, “heterocyclic”, refers to cyclic (i.e., ring-containing) groups containing one or more heteroatoms (e.g., N, O, S, or the like) as part of the ring structure, and having in the range of 3 up to 14 carbon atoms and “substituted heterocyclic” refers to heterocyclic groups further bearing one or more substituents as set forth above.
In certain embodiments, there are provided compounds of structures I-III wherein E 1 , E 3 , and E 4 are —O, and E 2 is —NH.
In certain embodiments, there are provided compounds of structures I-III wherein R 1 and R 2 are —H, alkyl, or substituted alkyl, and R 3 is hydroxy or alkoxy. In some embodiments, R 1 is substituted alkyl. Exemplary substituted alkyls contemplated for use include halogenated alkyls, such as for example chlorinated alkyls.
The compounds of the invention may be formulated into pharmaceutical compositions as natural or salt forms. Pharmaceutically acceptable non-toxic salts include the base addition salts (formed with free carboxyl or other anionic groups) which may be derived from inorganic bases such as, for example, sodium, potassium, ammonium, calcium, or ferric hydroxides, and such organic bases as isopropylamine, trimethylamine, 2-ethylamino-ethanol, histidine, procaine, and the like. Such salts may also be formed as acid addition salts with any free cationic groups and will generally be formed with inorganic acids such as, for example, hydrochloric, sulfuric, or phosphoric acids, or organic acids such as acetic, p-toluenesulfonic, methanesulfonic acid, oxalic, tartaric, mandelic, and the like. Salts of the invention include amine salts formed by the protonation of an amino group with inorganic acids such as hydrochloric acid, hydrobromic acid, hydroiodic acid, sulfuric acid, phosphoric acid, and the like. Salts of the invention also include amine salts formed by the protonation of an amino group with suitable organic acids, such as p-toluenesulfonic acid, acetic acid, and the like. Additional excipients which are contemplated for use in the practice of the present invention are those available to those of ordinary skill in the art, for example, those found in the United States Pharmacopeia Vol. XXII and National Formulary Vol. XVII, U.S. Pharmacopeia Convention, Inc., Rockville, Md. (1989), the relevant contents of which is incorporated herein by reference.
The compounds according to this invention may contain one or more asymmetric carbon atoms and thus occur as racemates and racemic mixtures, single enantiomers, diastereomeric mixtures and individual diastereomers. The term “stereoisomer” refers to chemical compounds which differ from each other only in the way that the different groups in the molecules are oriented in space. Stereoisomers have the same molecular weight, chemical composition, and constitution as another, but with the atoms grouped differently. That is, certain identical chemical moieties are at different orientations in space and, therefore, when pure, have the ability to rotate the plane of polarized light. However, some pure stereoisomers may have an optical rotation that is so slight that it is undetectable with present instrumentation. All such isomeric forms of these compounds are expressly included in the present invention.
Each stereogenic carbon may be of R or S configuration. Although the specific compounds exemplified in this application may be depicted in a particular configuration, compounds having either the opposite stereochemistry at any given chiral center or mixtures thereof are also envisioned. When chiral centers are found in the derivatives of this invention, it is to be understood that this invention encompasses all possible stereoisomers. The terms “optically pure compound” or “optically pure isomer” refers to a single stereoisomer of a chiral compound regardless of the configuration of the compound.
Exemplary invention compounds of structure I are shown below:
Salinosporamide A exhibits a molecular structure having a variety of functional groups (lactone, alkylhalide, amide, hydroxide) that can be chemically modified to produce synthetic derivatives. Accordingly, exemplary invention compound Salinosporamide A provides an excellent lead structure for the development of synthetic and semisynthetic derivatives. Indeed, Salinosporamide A can be derivatized to improve pharmacokinetic and pharmacodynamic properties, which facilitate administration and increase utility of the derivatives as anti-neoplastic agents. Procedures for chemically modifying invention salinosporamide compounds to produce additional compounds within the scope of the present invention are available to those of ordinary skill in the art.
Salinosporamide A shows strong cytotoxic activity against human colon cancer cells in the HTC-116 cell assays. The IC 50 of 11 ng/mL exceeds the activity of etoposide (see FIG. 3 , IC 50 828 ng/mL), an anticancer drug used for treatment of a number of cancers, by almost two orders of magnitude (see FIG. 4 ). This high activity makes invention salinosporamides excellent candidates for use in the treatment of various human cancers, especially slow growing, refractile cancers for which there are no therapies. Salinosporamide A is specific to inhibition of mammalian cells and shows little antifungal activity against Candida albicans (IC 50 250 μg/mL) and no antibacterial activity ( Staphylococcus aureus, Enterococcus faecium ). The IC 50 of Salinosporamide A is far lower than the strongest chemotherapeutic agents currently in use or in clinical trials.
Salinosporamide A is a fermentation product of the marine actinomycete strains CNB392 and CNB476. These strains are members of the order Actinomycetales, which are high G+C gram positive bacteria. The novelty of CNB392 and CNB476 is at the genus level. Invention compounds set forth herein are produced by certain “ Salinospora ” sp. In some embodiments, invention compounds are produced by “ Salinospora ” sp. strains CNB392 and CNB476. To that end, the CNB392 and CNB476 strains of “ Salinospora ” sp. were deposited on Jun. 20, 2003, pursuant to the Budapest Treaty on the International Deposit of Microorganisms for the Purposes of Patent Procedure with the Patent Culture Depository of the American Type Culture Collection, 12301 Parklawn Drive, Rockville, Md. 20852 U.S.A. under ATCC Accession Nos. —————— and PTA-5275, respectively.
As is the case with other organisms, the characteristics of “ Salinospora ” sp. are subject to variation. For example, recombinants, variants, or mutants of the specified strain may be obtained by treatment with various known physical and chemical mutagens, such as ultraviolet ray, X-rays, gamma rays, and N-methyl-N′-nitro-N-nitrosoguanidine. All natural and induced variants, mutants, and recombinants of the specified strain which retain the characteristic of producing a compound of the invention are intended to be within the scope of the claimed invention.
Invention compounds can be prepared, for example, by bacterial fermentation, which generates the compounds in sufficient amounts for pharmaceutical drug development and for clinical trials. In some embodiments, invention compounds are produced by fermentation of the actinomycete strains CNB392 and CNB476 in A1Bfe+C or CKA-liquid media. Essential trace elements which are necessary for the growth and development of the culture should also be included in the culture medium. Such trace elements commonly occur as impurities in other constituents of the medium in amounts sufficient to meet the growth requirements of the organisms. It may be desirable to add small amounts (i.e. 0.2 mL/L) of an antifoam agent such as polypropylene glycol (M. W. about 2000) to large scale cultivation media if foaming becomes a problem. The organic metabolites are isolated by adsorption onto an amberlite XAD-16 resin. For example, Salinosporamide A is isolated by elution of the XAD-16 resin with methanol:dichlormethane 1:1, which affords about 105 mg crude extract per liter of culture. Salinosporamide A is then isolated from the crude extract by reversed-phase flash chromatography followed by reverse-phase HPLC and normal phase HPLC, which yields 6.7 mg of Salinosporamide A. FIG. 5 sets forth a block diagram outlining isolation and separation protocols for invention compounds.
The structure of Salinosporamide A was elucidated by a variety of NMR techniques, mass spectroscopy, IR, and UV spectroscopy, as set forth in FIGS. 6-14 .
The absolute structure of salinosporamide A, and confirmation of the overall structure of salinosporamide A, was achieved by single-crystal X-ray diffraction analysis (see Example 3).
The present invention also provides articles of manufacture including packaging material and a pharmaceutical composition contained within the packaging material, wherein the packaging material comprises a label which indicates that the pharmaceutical composition can be used for treatment of disorders and wherein the pharmaceutical composition includes a compound according to the present invention. Thus, in one aspect, the invention provides a pharmaceutical composition including a compound of the invention, wherein the compound is present in a concentration effective to treat cell proliferative disorders. The concentration can be determined by one of skill in the art according to standard treatment regimen or as determined by an in vivo animal assay, for example.
Pharmaceutical compositions employed as a component of invention articles of manufacture can be used in the form of a solid, a solution, an emulsion, a dispersion, a micelle, a liposome, and the like, wherein the resulting composition contains one or more invention compounds as an active ingredient, in admixture with an organic or inorganic carrier or excipient suitable for enteral or parenteral applications. Compounds employed for use as a component of invention articles of manufacture may be combined, for example, with the usual non-toxic, pharmaceutically acceptable carriers for tablets, pellets, capsules, suppositories, solutions, emulsions, suspensions, and any other form suitable for use. The carriers which can be used include glucose, lactose, gum acacia, gelatin, mannitol, starch paste, magnesium trisilicate, talc, corn starch, keratin, colloidal silica, potato starch, urea, medium chain length triglycerides, dextrans, and other carriers suitable for use in manufacturing preparations, in solid, semisolid, or liquid form. In addition auxiliary, stabilizing, thickening and coloring agents and perfumes may be used.
The compositions of the present invention may contain other therapeutic agents as described below, and may be formulated, for example, by employing conventional solid or liquid vehicles or diluents, as well as pharmaceutical additives of a type appropriate to the mode of desired administration (for example, excipients, binders, preservatives, stabilizers, flavors, etc.) according to techniques such as those well known in the art of pharmaceutical formulation.
Invention pharmaceutical compositions may be administered by any suitable means, for example, orally, such as in the form of tablets, capsules, granules or powders; sublingually; buccally; parenterally, such as by subcutaneous, intravenous, intramuscular, or intracisternal injection or infusion techniques (e.g., as sterile injectable aqueous or non-aqueous solutions or suspensions); nasally such as by inhalation spray; topically, such as in the form of a cream or ointment; or rectally such as in the form of suppositories; in dosage unit formulations containing non-toxic, pharmaceutically acceptable vehicles or diluents. Invention compounds may, for example, be administered in a form suitable for immediate release or extended release. Immediate release or extended release may be achieved by the use of suitable pharmaceutical compositions comprising invention compounds, or, particularly in the case of extended release, by the use of devices such as subcutaneous implants or osmotic pumps. Invention compounds may also be administered liposomally.
The invention further provides methods for using invention salinosporamide compounds of structures (I)-(VI) to inhibit the proliferation of mammalian cells by contacting these cells with an invention salinosporamide compound in an amount sufficient to inhibit the proliferation of the mammalian cell. One embodiment is a method to inhibit the proliferation of hyperproliferative mammalian cells. For purposes of this invention, “hyperproliferative mammalian cells” are mammalian cells which are not subject to the characteristic limitations of growth, e.g., programmed cell death (apoptosis). A further preferred embodiment is when the mammalian cell is human. The invention further provides contacting the mammalian cell with at least one invention salinosporamide compound and at least one additional anti-neoplastic agent.
In another embodiment, there are provided methods for treating a mammalian cell proliferative disorder, comprising administering to a subject in need thereof a therapeutically effective amount of a compound of structures (I)-(VI). Cell proliferative disorders that can be effectively treated by the methods of the invention include disorders characterized by the formation of neoplasms. As such, invention compounds are anti-neoplastic agents. As used herein, “neoplastic” pertains to a neoplasm, which is an abnormal growth, such growth occurring because of a proliferation of cells not subject to the usual limitations of growth. As used herein, “anti-neoplastic agent” is any compound, composition, admixture, co-mixture or blend which inhibits, eliminates, retards or reverses the neoplastic phenotype of a cell. In certain embodiments, the neoplasms are selected from mammary, small-cell lung, non-small-cell lung, colorectal, leukemia, melanoma, pancreatic adenocarcinoma, central nervous system (CNS), ovarian, prostate, sarcoma of soft tissue or bone, head and neck, gastric which includes thyroid and non-Hodgkin's disease, stomach, myeloma, bladder, renal, neuroendocrine which includes thyroid and non-Hodgkin's disease and Hodgkin's disease neoplasms. In one embodiment, the neoplasms are colorectal.
Chemotherapy, surgery, radiation therapy, therapy with biologic response modifiers, and immunotherapy are currently used in the treatment of cancer. Each mode of therapy has specific indications which are known to those of ordinary skill in the art, and one or all may be employed in an attempt to achieve total destruction of neoplastic cells. Chemotherapy utilizing one or more invention salinosporamide compounds is provided by the present invention. Moreover, combination chemotherapy, chemotherapy utilizing invention salinosporamide compounds in combination with other neoplastic agents, is also provided by the invention as combination therapy is generally more effective than the use of single anti-neoplastic agents. Thus, a further aspect of the present invention provides compositions containing a therapeutically effective amount of at least one invention salinosporamide compound in combination with at least one other anti-neoplastic agent. Such compositions can also be provided together with physiologically tolerable liquid, gel or solid carriers, diluents, adjuvants and excipients. Such carriers, diluents, adjuvants and excipients may be found in the United States Pharmacopeia Vol. XXII and National Formulary Vol XVII, U.S. Pharmacopeia Convention, Inc., Rockville, Md. (1989), the contents of which are herein incorporated by reference. Additional modes of treatment are provided in AHFS Drug Information, 1993 ed. by the American Hospital Formulary Service, pp. 522-660, the contents of which are herein incorporated by reference.
Anti-neoplastic agents which may be utilized in combination with an invention salinosporamide compound include those provided in The Merck Index, 11th ed. Merck & Co., Inc. (1989) pp. Ther 16-17, the contents of which are hereby incorporated by reference. In a further embodiment of the invention, anti-neoplastic agents may be antimetabolites which may include, but are not limited to, methotrexate, 5-fluorouracil, 6-mercaptopurine, cytosine arabinoside, hydroxyurea, and 2-chlorodeoxyadenosine. In another embodiment of the present invention, the anti-neoplastic agents contemplated are alkylating agents which may include, but are not limited to, cyclophosphamide, melphalan, busulfan, paraplatin, chlorambucil, and nitrogen mustard. In a further embodiment of the invention, the antineoplastic agents are plant alkaloids which may include, but are not limited to, vincristine, vinblastine, taxol, and etoposide. In a further embodiment of the invention, the anti-neoplastic agents contemplated are antibiotics which may include, but are not limited to, doxorubicin (adriamycin), daunorubicin, mitomycin c, and bleomycin. In a further embodiment of the invention, the anti-neoplastic agents contemplated are hormones which may include, but are not limited to, calusterone, diomostavolone, propionate, epitiostanol, mepitiostane, testolactone, tamoxifen, polyestradiol phosphate, megesterol acetate, flutamide, nilutamide, and trilotane. In a further embodiment of the invention, the anti-neoplastic agents contemplated include enzymes which may include, but are not limited to, L-Asparaginase or aminoacridine derivatives which may include, but are not limited to, amsacrine. Additional anti-neoplastic agents include those provided in Skeel, Roland T., “Antineoplastic Drugs and Biologic Response Modifier: Classification, Use and Toxicity of Clinically Useful Agents,” Handbook of Cancer Chemotherapy (3rd ed.), Little Brown & Co. (1991), the contents of which are herein incorporated by reference.
In addition to primates, such as humans, a variety of other mammals can be treated according to the method of the present invention. For instance, mammals including, but not limited to, cows, sheep, goats, horses, dogs, cats, guinea pigs, rats or other bovine, ovine, equine, canine, feline, rodent or murine species can be treated.
The term “therapeutically effective amount” means the amount of the subject compound that will elicit the biological or medical response of a tissue, system, animal or human that is being sought by the researcher, veterinarian, medical doctor or other clinician, e.g., lessening of the effects/symptoms of cell proliferative disorders.
By “pharmaceutically acceptable” it is meant the carrier, diluent or excipient must be compatible with the other ingredients of the formulation and not deleterious to the recipient thereof.
The terms “administration of” and or “administering a” compound should be understood to mean providing a compound of the invention to the individual in need of treatment. Administration of the invention compounds can be prior to, simultaneously with, or after administration of another therapeutic agent or other anti-neoplastic agent.
The pharmaceutical compositions for the administration of the compounds of this invention may conveniently be presented in dosage unit form and may be prepared by any of the methods well known in the art of pharmacy. All methods include the step of bringing the active ingredient into association with the carrier which constitutes one or more accessory ingredients. In general, the pharmaceutical compositions are prepared by uniformly and intimately bringing the active ingredient into association with a liquid carrier or a finely divided solid carrier or both, and then, if necessary, shaping the product into the desired formulation. In the pharmaceutical composition the active object compound is included in an amount sufficient to produce the desired effect upon the process or condition of diseases.
The pharmaceutical compositions containing the active ingredient may be in a form suitable for oral use, for example, as tablets, troches, lozenges, aqueous or oily suspensions, dispersible powders or granules, emulsions, hard or soft capsules, or syrups or elixirs.
Compositions intended for oral use may be prepared according to any method known to the art for the manufacture of pharmaceutical compositions and such compositions may contain one or more agents selected from the group consisting of sweetening agents, flavoring agents, coloring agents and preserving agents in order to provide pharmaceutically elegant and palatable preparations. Tablets contain the active ingredient in admixture with non-toxic pharmaceutically acceptable excipients which are suitable for the manufacture of tablets. These excipients may be for example, inert diluents, such as calcium carbonate, sodium carbonate, lactose, calcium phosphate or sodium phosphate; granulating and disintegrating agents, for example, corn starch, or alginic acid; binding agents, for example starch, gelatin or acacia, and lubricating agents, for example magnesium stearate, stearic acid or talc. The tablets may be uncoated or they may be coated by known techniques to delay disintegration and absorption in the gastrointestinal tract and thereby provide a sustained action over a longer period. For example, a time delay material such as glyceryl monostearate or glyceryl distearate may be employed. They may also be coated to form osmotic therapeutic tablets for control release.
Formulations for oral use may also be presented as hard gelatin capsules wherein the active ingredient is mixed with an inert solid diluent, for example, calcium carbonate, calcium phosphate or kaolin, or as soft gelatin capsules wherein the active ingredient is mixed with water or an oil medium, for example peanut oil, liquid paraffin, or olive oil.
Aqueous suspensions contain the active materials in admixture with excipients suitable for the manufacture of aqueous suspensions. Such excipients are suspending agents, for example sodium carboxymethylcellulose, methylcellulose, hydroxy-propylmethylcellulose, sodium alginate, polyvinyl-pyrrolidone, gum tragacanth and gum acacia; dispersing or wetting agents may be a naturally-occurring phosphatide, for example lecithin, or condensation products of an alkylene oxide with fatty acids, for example polyoxyethylene stearate, or condensation products of ethylene oxide with long chain aliphatic alcohols, for example heptadecaethyleneoxycetanol, or condensation products of ethylene oxide with partial esters derived from fatty acids and a hexitol such as polyoxyethylene sorbitol monooleate, or condensation products of ethylene oxide with partial esters derived from fatty acids and hexitol anhydrides, for example polyethylene sorbitan monooleate. The aqueous suspensions may also contain one or more preservatives, for example ethyl, or n-propyl, p-hydroxybenzoate, one or more coloring agents, one or more flavoring agents, and one or more sweetening agents, such as sucrose or saccharin.
Oily suspensions may be formulated by suspending the active ingredient in a vegetable oil, for example arachis oil, olive oil, sesame oil or coconut oil, or in a mineral oil such as liquid paraffin. The oily suspensions may contain a thickening agent, for example beeswax, hard paraffin or cetyl alcohol. Sweetening agents such as those set forth above, and flavoring agents may be added to provide a palatable oral preparation. These compositions may be preserved by the addition of an anti-oxidant such as ascorbic acid.
Dispersible powders and granules suitable for preparation of an aqueous suspension by the addition of water provide the active ingredient in admixture with a dispersing or wetting agent, suspending agent and one or more preservatives. Suitable dispersing or wetting agents and suspending agents are exemplified by those already mentioned above. Additional excipients, for example sweetening, flavoring and coloring agents, may also be present.
Syrups and elixirs may be formulated with sweetening agents, for example glycerol, propylene glycol, sorbitol or sucrose. Such formulations may also contain a demulcent, a preservative and flavoring and coloring agents.
The pharmaceutical compositions may be in the form of a sterile injectable aqueous or oleagenous suspension. This suspension may be formulated according to the known art using those suitable dispersing or wetting agents and suspending agents which have been mentioned above. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example as a solution in 1,3-butane diol. Among the acceptable vehicles and solvents that may be employed are water, Ringer's solution and isotonic sodium chloride solution. In addition, sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose any bland fixed oil may be employed including synthetic mono- or diglycerides. In addition, fatty acids such as oleic acid find use in the preparation of injectables.
The compounds of the present invention may also be administered in the form of suppositories for rectal administration of the drug. These compositions can be prepared by mixing the drug with a suitable non-irritating excipient which is solid at ordinary temperatures but liquid at the rectal temperature and will therefore melt in the rectum to release the drug. Such materials are cocoa butter and polyethylene glycols.
For topical use, creams, ointments, jellies, solutions or suspensions, etc., containing the compounds of the present invention are employed.
Compounds and compositions of the invention can be administered to mammals for veterinary use, such as for domestic animals, and clinical use in humans in a manner similar to other therapeutic agents. In general, the dosage required for therapeutic efficacy will vary according to the type of use and mode of administration, as well as the particularized requirements of individual hosts. Ordinarily, dosages will range from about 0.001 to 1000 μg/kg, more usually 0.01 to 10 μg/kg, of the host body weight. Alternatively, dosages within these ranges can be administered by constant infusion over an extended period of time, usually exceeding 24 hours, until the desired therapeutic benefits have been obtained. It will be understood, however, that the specific dose level and frequency of dosage for any particular patient may be varied and will depend upon a variety of factors including the activity of the specific compound employed, the metabolic stability and length of action of that compound, the age, body weight, general health, sex, diet, mode and time of administration, rate of excretion, drug combination, the severity of the particular condition, and the host undergoing therapy.
The invention will now be described in greater detail by reference to the following non-limiting examples.
EXAMPLES
Methods and Materials
HPLC-Purification of invention compounds was accomplished by RP-MPLC on C18-solid phase (Aldrich) using a step gradient on Kontes Flex-columns (15×7 mm). Semipreparative HPLC was performed on an isocratic HPLC system with a Waters pump 6000H on normal phase column Si-Dynamas-60 Å (250×5 mm) or reversed phase column C18-Dynamax-60 Å, flow 2 mL/minute, with a differential refractomeric detector Waters R401.
LC-MS-The LC-MS chromatography was performed on a Hewlett-Packard system series HP1100 with DAD and MSD1100 detection. The separation was accomplished on reversed phase C18 (Agilent Hypersil ODS 5 μm, column dimension 4.6×100 mm), flow rate 0.7 mL/minute using a standard gradient: 10% acetonitrile, 15 minutes; 98% acetonitrile (Burdick & Jackson high purity solvents). The MS-detection was in ESI positive mode, capillary voltage 3500 eV, fragmentation voltage 70 eV, mass range m/z 100-1000. The APCI-mode was measured at a flow rate of 0.5 mL/minute, positive detection, capillary voltage 3000 eV, fragmentation voltage 70 eV.
NMR-NMR spectra were measured on a Varian 300 MHz gradient field spectrometer with inverse-mode for 1 H or 2D-NMR spectra. The 13C and DEPT spectra were measured on a Varian 400 MHz, broad band instrument. The reference is set on the internal standard tetramethylsilane (TMS, 0.00 ppm).
MS-EI-Low resolution MS-EI spectra were performed on a Hewlett-Packard mass spectrometer with magnetic sector field device, heating rate 20° C./minute up to 320° C., direct injection inlet.
FTMS-MALDI-High resolution MS data were obtained by MALDI operating mode on an IonSpec Ultima FT Mass Spectrometer.
IR-Infrared spectra were measured on a Perkin-Elmer FT infrared spectrophotometer using NaCl windows.
Example 1
Isolation and Characterization of “ Salinospora ” Species, Culture Nos. CNB392 and CNB476
CNB392 and CNB476 possess signature nucleotides within their 16S rDNA which separate these strains phylogenetically from all other members of the family Micromonosporaceae (see FIG. 15 ) These signature nucleotides have been determined to be a definitive marker for members of this group which also have a physiological growth requirement of sodium. Signature nucleotides were aligned to E. coli positions 27-1492 using all existing members of the Micromonosporaceae in the Ribosomal Database Project as of 1-31-01. For the “ Salinospora ” clade, 45 partially sequenced morphotypes displayed all the signature nucleotides from positions 207-468. The seven “ Salinospora ” isolates sequenced almost in their entirety (see FIG. 2 ) displayed all of the signatures in FIG. 15 .
The strains CNB392 and CNB476 form bright orange to black colonies on agar and lacks aerial mycelia. Dark brown and bright orange diffusible pigments are produced depending upon cellular growth stage. Spores blacken the colony surface and are borne on substrate mycelia. Vegetative mycelia are finely branched and do not fragment. Spores are produced singly or in clusters. Neither sporangia nor spore motility has been observed for these strains. CNB392 and CNB476 have an obligate growth requirement for sodium and will not grow on typical media used for maintenance of other generic members of the Micromonosporaceae. CNB392 and CNB476 have been found to grow optimally on solid media TCG or M1 at 30° C.
TCG M1 3 grams tryptone 10 grams starch 5 grams casitone 4 grams yeast extract 4 grams glucose 2 grams peptone 18 grams agar (optional) 18 grams agar (optional) 1 liter filtered seawater 1 liter filtered seawater
Fermentation
CNB392 and CNB476 are cultured in shaken A1Bfe+C or CKA-liquid media, 1 liter at 35° C. for 9 days. After 4 days 20 grams Amberlite XAD-16 resin (Sigma, nonionic polymeric adsorbent) is added.
A1Bfe + C CKA 10 grams starch 5 grams starch 4 grams yeast extract 4 mL hydrosolubles (50%) 2 grams peptone 2 grams menhaden meal 1 gram CaCO 3 2 grams kelp powder 5 mL KBr (aqueous solution, 20 grams/ 2 grams chitosan liter) 5 mL Fe 2 (SO 4 ) 3 × 4 H 2 O (8 grams/liter) 1 liter filtered seawater 1 liter filtered seawater
Extraction
The XAD-16 resin is filtered and the organic extract is eluted with 1 liter ethylacetate followed by 1 liter methanol. The filtrate is then extracted with ethylacetate (3×200 mL). The crude extract from the XAD adsorption is 105 mg. Cytotoxicity on the human colon cancer cell HCT-116 assay is IC50<0.076 μg/mL.
Isolation of Salinosporamide A from CNB392
The crude extract was flash-chromatographed over C18 reversed phase (RP) using a step gradient ( FIG. 5 ). The HCT-116 assay resulted in two active fractions, CNB392-5 and CNB392-6. The combined active fractions (51.7 mg), HCT-116<0.076 μg/mL) were then chromatographed on an isocratic RP-HPLC, using 85% methanol at 2 mL/minute flow as eluent and using refractive index detection. The active fraction CNB392-5/6 (7.6 mg, HCT-116<0.076 μg/mL) was purified on an isocratic normal phase HPLC on silica gel with ethyl acetate:isooctane (9:1) at 2 mL/minute. Salinosporamide A ( FIG. 1 ) was isolated as a colorless, amorphous solid in 6.7 mg per 1 liter yield (6.4%). TLC on silica gel (dichloromethane:methanol 9:1) shows Salinosporamide A at r f =0.6, no UV extinction or fluorescence at 256 nm, yellow with H 2 SO 4 /ethanol, dark red-brown with Godin reagent (vanillin/H 2 SO 4 /HClO 4 ). Salinosporamide A is soluble in CHCl 3 , methanol, and other polar solvents like DMSO, acetone, acetonitrile, benzene, pyridine, N,N-dimethylformamide, and the like. 1 H NMR: (d 5 -pyridine, 300 MHz) 1.37/1.66 (2H, m, CH 2 ), 1, 70.2.29 (2H, m, CH 2 ), 1.91 (2H, broad, CH 2 ), 2.07 (3H, s, CH 3 ), 2.32/2.48 (2H, ddd, 3 J=7.0 Hz, CH 2 ), 2.85 (1H, broad, m, CH), 3.17 (1H, dd, 3 J=10 Hz, CH), 4.01/4.13 (2H, m, CH 2 ), 4.25 (1H, d, 3 J=9.0 Hz, CH), 4.98 (1H, broad, OH), 5.88, (1H, ddd, 3 J=10 Hz, CH), 6.41 (1H, broad d, 3 J=10 Hz, CH) 10.62 (1H, s, NH).
13 C NMR/DEPT: (d 5 -pyridine, 400 MHz) 176.4 (COOR), 169.0 (CONH), 128.8 (═CH), 128.4 (═CH), 86.1 (C q ), 80.2 (C q ), 70.9 (CH), 46.2 (CH), 43.2 (CH 2 ), 39.2 (CH), 29.0 (CH 2 ), 26.5 (CH 2 ), 25.3 (CH 2 ), 21.7 (CH 2 ), 20.0 (CH 3 )
LC-MS (ESI) t r =10.0 minutes, flow 0.7 mL/minute
m/z: (M+H) + 314, (M+Na) + 336; fragments: (M+H—CO 2 ) + 292, (M+H—CO 2 —H 2 O) + 270, 252, 204. Cl pattern: (M+H, 100%) + 314, (M+H, 30%) + 316.
LC MS (APCI): t r =11.7 minutes, flow 0.5 mL/minute
m/z: (M+H) + 314, fragments: (M+H—CO 2 —H 2 O) + 270, 252, 232, 216, 160. Cl pattern: (M+H, 100%) + 314, (M+H, 30%) + 316.
EI: m/z: 269, 251, 235, 217, 204, 188 (100%), 160, 152, 138, 126, 110, 81.
FTMS-MALDI: m/z: (M+H) + 314.1144
FT-IR: (cm −1 ) 2920, 2344, s, 1819 m, 1702 s, 1255, 1085 s, 1020 s, 797 s.
Molecular formula: C 15 H 20 ClNO 4
Example 2
Bioactivity Assays
Salinosporamide A shows strong activity against human colon cancer cells with an IC 50 of 0.011 μg/mL (see FIG. 4 ). The screening on antibacterial or antifungal activity shows no significant activity, see Table 1.
TABLE 1
IC 50 of Salinosporamide A,
Assay
(μg/mL)
HCT-116
0.011
Candida albicans
250
Candida albicans (amphoterocin B resistant)
NSA*
Staphylococcus aureus (methecillin resistant)
NSA*
Enterococcus faecium (vanomycin resistant)
NSA*
*NSA = no significant activity
Example 3
Determination of Absolute Stereochemistry
Crystallization of a compound of structure I from ethyl acetate/iso-octane resulted in single, cubic crystals, which diffracted as a monoclinic system P2(1). The unusual high unit-cell volume of 3009 Å hosted four independent molecules in which different conformational positions were observed for the flexible chloroethyl substituent. The assignment of the absolute structure from the diffraction anisotropy of the chlorine substituent resolved the absolute stereochemistry of salinosporamide A as 2R, 3S, 4R, 5S, 6S ( FIGS. 16 and 17 ) with a Flack parameter of 0.01 and an esd of 0.03.
Although the invention has been described with reference to the above examples, it will be understood that modifications and variations are encompassed within the spirit and scope of the invention. Accordingly, the invention is limited only by the following claims.
|
The present invention is based on the discovery that certain fermentation products of the marine actinomycete strains CNB392 and CNB476 are effective inhibitors of hyperproliferative mammalian cells. The CNB392 and CNB476 strains lie within the family Micromonosporaceae, and the generic epithet Salinospora has been proposed for this obligate marine group. The reaction products produced by this strain are classified as salinosporamides, and are particularly advantageous in treating neoplastic disorders due to their low molecular weight, low IC 50 values, high pharmaceutical potency, and selectivity for cancer cells over fungi.
| 2
|
BACKGROUND OF THE INVENTION
[0001] Standard microelectromechanical systems (MEMS) processing techniques create structures that are symmetric in the z axis (out of the wafer's surface) but can vary in the x and y axes (in the plane of the wafer's surface). This leads to devices which can only move in the x/y plane. Presently, creating asymmetry in the z-axis can be performed by deflecting with stiction plates or by selective thinning. Deflecting with stiction plates leads to devices which are sensitive to z motion, but is not easily implemented for multiple z-offsets in both directions and also requires more steps and additional processing layers, thereby costing more money. Selective thinning is performed by thinning one set of teeth in the Z-direction, but this requires an extra mask and additional etches, and it is also rather inaccurate.
[0002] Thus, there exists a need for methods to easily form z-offsets in MEMS devices.
BRIEF SUMMARY OF THE INVENTION
[0003] A microelectromechanical system (MEMS) device with a mechanism layer having a first part and a second part, and at least one cover for sealing the mechanism layer. The inner surface of at least one of the covers is structured such that a protruding structure is present on the inner surface of the cover and wherein the protruding structure mechanically causes the first part to be deflected out of a plane associated with the second part.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIGS. 1A, 1B , and 1 C illustrate a cross-sectional side view before assembly, a cross-sectional side view after assembly, and a cross-sectional top view of a microelectromechanical system (MEMS) comb structure device in accordance with one embodiment of the invention;
[0005] FIGS. 2A, 2B , and 2 C illustrate a cross-sectional side view before assembly, a cross-sectional side view after assembly, and a cross-sectional top view of an alternative embodiment of the invention; and
[0006] FIG. 3 illustrates a cross-sectional top view of an additional embodiment of the invention.
[0007] FIG. 4 illustrates a schematic view of a system including one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0008] FIGS. 1A, 1B and 1 C illustrate a side view before assembly, a side view after assembly and a top view of a microelectromechanical system (MEMS) comb structure device 30 formed in accordance with one embodiment of the invention. FIGS. 1A and 1B show that the device 30 has a top cover 4 and a bottom cover 5 enclosing a mechanism layer 32 that includes a first side 10 , a second side 12 directly opposite the first side 10 , a movable part 14 , a first fixed part 16 , a second fixed part 18 , and flexures 20 . Flexures may also be referred to as torsional flexures or as hinges. FIG. 1A illustrates a cross-sectional side view of the comb structure device 30 shown in FIG. 1B before the top cover 4 and the bottom cover 5 have been attached to the device 30 . For purposes of FIGS. 1B and 1C , the positive z direction is defined to run from the bottom cover 5 to the top cover 4 such that it is orthogonal to the outer surfaces of both of the covers and orthogonal to the mechanism layer. The top cover 4 has a structure 6 protruding from its inner surface that causes the second fixed part 18 to be mechanically deflected in the negative z direction and away from the plane associated with the movable part 14 when the top cover 4 is attached to the first side 10 and the second side 12 . Bottom cover 5 has a structure 8 protruding from its inner surface that causes the first fixed part 16 to be mechanically deflected in the positive z direction and away from the plane associated with the movable part 14 when the bottom cover 5 is attached to the first side 10 and the second side 12 .
[0009] Cross-sectional top view FIG. 1C shows that the mechanism layer also has a third side 40 and a fourth side 42 so that the movable part 14 , the first fixed part 16 , and the second fixed part 18 are surrounded on four sides by the first side 10 , the second side 12 , the third side 40 , and the fourth side 42 . The movable part 14 is held in place by hinges 24 and 26 attached to the third side 40 and the fourth side 42 which allow the movable part 14 to rotate about the hinges 24 and 26 but keep the movable part relatively fixed with respect to translational movement in the x/y plane. FIG. 1C also illustrates that the movable part 14 is formed such that a series of comb electrodes protrude towards the first fixed part 16 and the second fixed part 18 . The first fixed part 16 and the second fixed part 18 include a series of comb electrodes protruding from the side facing the movable part 14 . The comb electrodes of the first fixed part 16 and the second fixed part 18 are interleaved with the comb electrodes protruding from the sides of the movable part 14 . In another embodiment, a non-sealed device may be formed without using the first side 10 , the second side 12 , the third side 40 , and the fourth side 42 . An alternative embodiment based on the non-sealed device could also be formed, where flexures 20 are temporary structures that are put in a dicing space between each comb structure device 30 , and removed in a final configuration. In some embodiments, structure 6 will be bonded to the second fixed part 18 and structure 8 will be bonded to the first fixed part 16 .
[0010] FIGS. 2A, 2B , and 2 C illustrate a cross-sectional side view before assembly, a cross-sectional side view after assembly, and a cross-sectional top view of an alternative embodiment of the invention. FIGS. 2A and 2B show that a device 80 has a top cover 100 and a bottom cover 102 enclosing a mechanism layer 120 that includes a first side 106 , a second side 108 directly opposite the first side 106 , a movable part 110 , a fixed part 112 , and flexure 20 . FIG. 2A illustrates a cross-sectional side view of the comb structure device 80 shown in FIG. 2B before the top cover 100 and the bottom cover 102 have been attached to the device 80 . For purposes of FIGS. 2B and 2C , the positive z direction is defined to run from the bottom cover 102 to the top cover 100 such that it is orthogonal to the outer surfaces of both of the covers and the mechanism layer 120 . The top cover 100 has a structure 104 protruding from its inner surface that causes the fixed part 112 to be mechanically deflected in the negative z direction and away from the plane associated with the movable part 110 when the top cover 100 is attached to the first side 106 and the second side 108 . Bottom cover 102 is attached to the first side 106 and the second side 108 .
[0011] Cross-sectional top view FIG. 2C shows that the mechanism layer also has a third side 130 and a fourth side 132 so that the movable part 110 and the fixed part 112 are surrounded on four sides by the first side 106 , the second side 108 , the third side 130 , and the fourth side 132 . The movable part 110 is held in place by hinges 134 and 136 attached to the third side 130 and the fourth side 132 which allow the movable part 110 to rotate about the hinges but keep the movable part relatively fixed with respect to translational movement in the x-y plane. FIG. 2C also illustrates that the movable part 110 is formed such that a series of comb electrodes protrude on the side facing the interior of the device. The fixed part 112 is also shown to each have a series of comb electrodes protruding from the side facing the movable part 110 . The comb electrodes of the fixed part 112 are interleaved with the comb electrodes protruding from the side of the movable part 110 .
[0012] FIG. 3 illustrates a cross-sectional top view of a device 150 that is an additional embodiment of the invention. In this embodiment, more than two parts are deflected. Three fixed parts 152 are deflected up and three fixed parts 154 are deflected down relative to a central comb part 156 .
[0013] FIG. 4 illustrates a schematic view of a system 190 including one embodiment of the present invention. A comb structure accelerometer 200 such as that described in FIGS. 1B and 1C in signal communication with rebalance electronics 202 . The rebalance electronics 202 rebalances the comb structure accelerometer 200 . Sense electronics 204 , receives signals from the comb structure accelerometer 200 and produces a relevant output signal 206 to be used in further processing or storage. The signal 206 can be fed back into the rebalance electronics 202 , if closed loop operation is desired.
[0014] The structures 6 , 8 , and 104 protruding from the inner surfaces of the covers 4 , 5 , and 100 and the covers 4 , 5 , and 100 themselves may be formed of a monolithic material such as silicon or pyrex, for example, or the structures 6 , 8 , and 104 may be attached or deposited on the surface of each cover in alternative embodiments. If structures 6 , 8 , or 104 are attached or deposited on the surface of covers 4 , 5 , or 100 , structures 6 , 8 , or 104 may be made of the same material such as silicon or pyrex, for example, or a different material such as a metal, for example, as covers 4 , 5 , and 100 . Also, for example, the structures 6 , 8 , and 104 protruding from the inner surfaces of the covers 4 , 5 , and 100 could be used to deflect the movable parts 14 and 110 of the devices 30 and 80 instead of or in addition to deflecting the fixed parts 16 , 18 , and 112 .
[0015] While the preferred embodiment of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. Additionally, the MEMS device itself may be a sensor or an actuator acting as a sense mechanism or a drive mechanism. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined entirely by reference to the claims that follow.
|
A microelectromechanical system (MEMS) device with a mechanism layer having a first part and a second part, and at least one cover for sealing the mechanism layer. The inner surface of at least one of the covers is structured such that a protruding structure is present on the inner surface of the cover and wherein the protruding structure mechanically causes the first part to be deflected out of a plane associated with the second part.
| 6
|
BACKGROUND OF THE INVENTION
[0001] The invention relates to a surgical clip applier.
[0002] Surgical clip appliers are used to apply surgical clips or fasteners to tissues and other areas of a surgical site during the course of various surgical procedures. Clip appliers include automatic and manual appliers, and the present invention is directed toward manual appliers.
[0003] Known clip appliers include jaws which are used to hold a clip and a mechanism which is used to close the jaws so that the clip can be closed upon the desired location. These devices must be precise, reliable and user friendly for the surgeon. Producing these qualities, however, frequently requires the applier to be complicated and expensive, which is not conducive to a single-use item. In addition, the complex structures incorporated into such apparatus are problematic during cleaning and sterilization.
[0004] Another issue with known clip appliers is over-opening of the jaws. This is problematic because if jaws open too far, a clip held in the jaws can inadvertently be dropped, potentially within the surgical site with obvious complications resulting therefrom.
[0005] The focus of the present invention is to overcome the above-identified disadvantages.
SUMMARY OF THE INVENTION
[0006] In accordance with the invention, the foregoing issues are addressed. As disclosed herein, a surgical clip applier is provided which has a setting screw advantageously positioned to allow precise setting of a maximum open width of the jaws. Further, the clip applier of the present invention can have jaws which are easily installed and removed from the body of the clip applier, thus making the jaws reposable and allowing for extended use of the components of the arms or handle portion of the applier.
[0007] According to the invention, a surgical clip applier is provided which comprises a first arm and a second arm pivotable relative to each other and defining proximal ends for manually controlling the applier, and distal ends; jaws positioned between the distal ends such that pivot of the first arm relative to the second arm opens and closes the jaws; and a setting element movably mounted in one of the first arm and the second arm and extending into contact with the other of the first arm and the second arm to define a maximum open position of the first arm relative to the second arm, and wherein a change of position of the setting element adjusts the maximum open position.
[0008] The surgical clip applier may further comprise the following features, taken alone or in combination whenever it is technically possible.
[0009] The setting element may be a setting screw threadedly mounted in one of the first arm and the second arm and extending into contact with the other of the first arm and the second arm to define a maximum open position of the first arm relative to the second arm, and wherein rotation of the setting screw changes a position of the setting screw and thereby adjusts the maximum open position.
[0010] The first arm and the second arm may each define portions which are proximal of a pivot point between the first arm and the second arm such that the portions move toward each other during opening of the arms, wherein the setting element extends from the portion of the first arm toward the portion of the second arm.
[0011] The jaws may be releasably held between the distal ends.
[0012] The jaws may have a proximal groove sized to fit around a pivot between the first arm and the second arm, and a snap structure defined between the jaws and the distal ends to releasably hold the jaws between the proximal ends.
[0013] When the jaws are engaged with the distal ends for use of the applier, the groove may engage the pivot and the snap structure may be engaged.
[0014] The jaws may be configured such that squeezing the jaws toward each other disengages the snap structure.
[0015] The surgical clip applier may comprise at least one biasing member for resiliently biasing the jaws toward an open position.
[0016] The biasing member may comprise a first prong positioned along the first arm and a second prong positioned along the second arm to apply an opening force to the first arm and the second arm, wherein the prongs are parts of the jaws.
[0017] At least one of the prongs may have a knee for biaising the prong toward a bent configuration whenever the prong is straightened, the knee being further arranged to come into contact with the other prong then straighten the bent prong whenever the jaws are moved towards each other.
[0018] The biasing member may comprise an opening spring positioned relative to the first arm and the second arm to apply an opening force to the first arm and the second arm.
[0019] The first arm may be pivotably mounted to the second arm with at least one slidable plate on one arm engaged in a groove on the other arm.
[0020] The first arm may be pivotally mounted to the second arm with a screw assembly.
[0021] the first arm may be pivotably mounted to the second arm with a tapped rivet.
[0022] According to the invention, a method for assembling a surgical clip applier is provided which comprises the steps of: engaging a first arm with a second arm along curved surfaces defining a pivot point between the first arm and the second arm; pivoting the first arm toward the second arm to engage the curved surfaces of the pivot point against separation from each other; adjusting a setting element in one arm relative to the other arm to set a maximum open position of the first arm relative to the second arm; and inserting a jaws member into engagement with distal ends of the first arm and the second arm, whereby the clip applier is assembled and ready for use.
[0023] Other objects, advantages and details of the present invention will be further discussed hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] A detailed description of preferred embodiments of the invention follows, with reference to the attached drawings, wherein:
[0025] FIGS. 1 and 1A are perspective illustrations of a surgical clip applier in accordance with the present invention;
[0026] FIGS. 2 and 2A are enlarged perspective illustrations of the jaws and distal portion of the surgical clip applier in accordance with the present invention;
[0027] FIGS. 3 and 3A are top views similar to FIGS. 2 and 2A ;
[0028] FIGS. 4-7 illustrate installation and removal of jaws from a surgical clip applier in accordance with the present invention;
[0029] FIGS. 8 and 9 illustrate the snap in structure which hold jaws in the surgical clip applier in accordance with the present invention;
[0030] FIGS. 10 and 11 illustrate an additional opening spring which may be included in certain embodiments of the present invention;
[0031] FIG. 12 further illustrates aspects of the arms of the surgical clip applier as well as the pivot connection and setting screw;
[0032] FIGS. 13 and 14 illustrate one embodiment of the structure of the pivot connection of a surgical clip applier in accordance with the present invention;
[0033] FIGS. 15 and 16 illustrate alternate pivot connections;
[0034] FIGS. 17-22 illustrate a method for assembling a surgical clip applier in accordance with the present invention; and
[0035] FIGS. 23 and 23A illustrate another embodiment of the invention.
DETAILED DESCRIPTION
[0036] The invention relates to a surgical clip applier which has enhanced adjustability to a maximum open position, reposable jaws and improved simplicity from an assembly, use, and sterilization standpoint.
[0037] FIGS. 1 and 1A show a surgical clip applier 10 in accordance with the present invention, wherein FIG. 1A shows some components of FIG. 1 transparently to illustrate inner details. Applier 10 has a first arm 12 and a second arm 14 , which are pivotally connected with each other to form a scissor-like instrument. Proximal portions 16 , 18 of arms 12 , 14 can be formed as loops 20 or other suitable structures to facilitate the manual operation of the applier, for example by being gripped in one hand of a surgeon.
[0038] Shaft portions 22 lead from proximal portions 16 , toward a pivot point 24 and distal portions 26 , 28 extend from pivot point 24 .
[0039] Jaws 30 are positioned between distal portions 26 , 28 such that operation of arms 12 , 14 to pivot around pivot point 24 serves to open and close distal portions 26 , 28 and jaws 30 positioned therebetween.
[0040] As is well known to persons skilled in this art, jaws 30 are used to manually apply surgical clips, one at a time, to desired locations or tissues within a surgical site. Arms 12 , 14 define a scissor-like instrument which is manipulated by the surgeon or other person using the clip applier to open and close the jaws 30 such that a clip disposed between the jaws can be closed onto a desired location. After application of a clip, the jaws are opened and a new clip is positioned in the jaws for the next application.
[0041] Also considering FIGS. 2 and 2A , additional detail of the jaws 30 and distal portions 26 and 28 can be seen as can a setting element 32 which, in accordance with the invention, can advantageously be used to adjust the maximum open position of the clip applier 10 , preferably so that the jaws cannot accidentally open wide enough to inadvertently drop a clip before it is applied.
[0042] As shown, arms 12 , 14 have portions 34 , 36 which are positioned proximally of pivot point 24 , and setting element 32 is a screw which is advantageously threadedly engaged in one portion 34 so that it extends toward contact with the other portion 36 . Arms 12 , 14 are configured such that portions 34 , 36 move toward each other as arms 12 , 14 are opened. This can be accomplished, for example, by having portion 34 attached to arm 14 and having portion 36 attached to arm 12 . It should be readily appreciated that with such a configuration, spreading of arms 12 , 14 results in closing of portions 34 , 36 .
[0043] FIGS. 2 and 2A also show setting screw 32 threadedly engaged in portion 34 and extending toward contact with portion 36 . It should be appreciated that adjusting of setting screw 32 changes the position of setting screw 32 within portion 34 and thereby changes the relative position of arm 14 with respect to arm 12 at which setting screw 32 will contact portion 36 . Thus, adjusting setting screw 32 allows fine tuning and adjusting of the maximum open position of arms 12 , 14 and, therefore, jaws of clip applier 10 in accordance with the present invention.
[0044] FIGS. 3 and 3A show similar details as FIGS. 2 and 2A , from a top position, and additional details of jaws 30 can also be seen which will be discussed below.
[0045] In accordance with the invention, and as discussed above, it is desirable that the jaws 30 be removable for special sterilization, etc. between uses, and eventually for being discarded and replaced with new jaws. Further, this removable nature of the jaws allows jaws of different sizes to be used with the same handle. For example, one handle could be configured to use with small, small-medium and medium jaws for applying clips of corresponding sizes.
[0046] To this end, jaws 30 can advantageously be defined by a substantially flat member 38 having a proximal end and a distal end. The proximal end can advantageously having a groove 40 for passing around or engaging pivot point 24 , and two arms or prongs 42 extending distally from groove 40 to terminate in respective jaw members 44 . As will further be discussed below, each prong 42 advantageously has a snap structure which releasably engages with distal portions 26 , 28 so that jaws 30 can be installed into and then released from distal portions 26 , 28 as desired. It should also be noted that, as best seen in FIG. 2 , the actual jaw members 44 of jaws 30 , which hold clips to be applied, can be angled somewhat downwardly from the plane of the prongs 42 , and can also have channels defined at inwardly facing surfaces thereof, which channels serve to better hold a clip between the jaws.
[0047] In order to install jaws into a surgical clip applier in accordance with the present invention, one would follow the series of steps shown in FIGS. 4-6 . FIG. 4 shows jaws 30 outside of clip applier 10 , with groove 40 aligned with the distal portions 26 , 28 of applier 10 . Sliding the substantially flat member 38 of jaws 30 into the position shown in FIG. 5 aligns prongs 42 with ridges which extend longitudinally along distal portions 26 , 28 . Jaws 30 are pushed into applier 10 in this manner until the position in FIG. 6 is reached, wherein groove 40 engages pivot point 24 and a snapping structure between jaws 30 and distal portions 26 , 28 engages to hold jaws 30 in place. In this position ( FIG. 6 ), surgical clip applier 10 in accordance with the invention is ready for use.
[0048] When jaws 30 are to be removed from the clip applier, a pinching force (arrow A, FIG. 7 ) can be applied to jaw members 44 to disengage the snapping structure between jaws 30 and distal portions 26 , 28 and jaws 30 can then distally slide out from distal portions 26 , 28 as shown in FIG. 7 .
[0049] FIGS. 8 and 9 show an enlarged portion of the snap assembly between jaws 30 and distal portions 26 , 28 . FIG. 8 shows distal portion 28 having a shoulder 46 , and shows prong 42 having an oppositely directed shoulder 48 . Because jaws are resilient and flexible, prongs 42 of jaws 30 will laterally compress as jaws 30 are inserted into distal portions 26 , 28 , until shoulder 48 snaps past shoulder 46 into the position shown in FIG. 9 . In this position, shoulders 46 , 48 hold jaws 30 into distal portions 26 , 28 until removal of the jaws following the process shown in FIG. 7 .
[0050] FIGS. 10 and 11 further illustrate an additional feature of the present invention wherein an opening spring can be included and positioned between shaft portions 22 , at a position which is proximal of pivot points 24 . Opening spring 50 serves to provide an additional opening force, as well as a resistive force against closing, which can be desirable depending upon the use and user of the device. As shown, opening spring 50 can have a coil portion 52 and two arms 54 , 56 which can be extended into contact with shafts 22 as shown in FIG. 10 .
[0051] It should be appreciated that opening spring 50 is an optional feature in accordance with the present invention since jaws 30 are ideally designed to apply a sufficient opening force to distal portions 26 , 28 of arms 12 , 14 . Nevertheless, opening spring 50 can be incorporated into surgical clip applier 10 in accordance with the present invention, either in addition to or instead of the spring force which is otherwise generated by jaws 30 in accordance with the present invention.
[0052] FIG. 12 further illustrates the shape and features of portions of arms 12 , 14 in accordance with the present invention. Portions 34 , 36 are illustrated, as is setting screw 32 , and this figure also further illustrates the relationship between portions 34 and 36 , setting screw 32 and operation of the device in accordance with the present invention.
[0053] When applier 10 is to be opened, arms 12 , 14 are opened as shown by arrows B in FIG. 12 . It should be appreciated that this motion, translated to distal portions 26 , 28 around pivot point 24 would also result in an opening of distal portions 26 , 28 and jaws 30 positioned therebetween as shown by arrows C. Thus, portion 34 can be associated with arm 14 while portion 36 is associated with arm 12 . In this manner, when arms 12 , 14 and jaws 30 are opened as shown by arrows B, C, portions 34 , 36 move toward each other. Setting screw 32 engages portion 36 to stop opening of the arms and jaws in the pre-selected desired maximum position.
[0054] FIGS. 13 and 14 illustrate a preferred embodiment of a structure for pivot point 24 in accordance with the present invention, wherein portions of the arms 12 , 14 are in the form of plates 53 which can engage along rounded surfaces with grooves 55 of the other of first and second arm 12 , 14 . In this embodiment, no screws or rivets of any kind are needed, and the arms 12 , 14 engage each other along rounded surfaces that define a point of pivot therebetween. Once the plates 53 of one arm are engaged in grooves 55 of the other arm, the arms are pivotably held together in a desired position. The contacting edges of plates 53 and grooves 55 are referred to as rounded, and this rounding is in an arc which centers on the pivot point between arms 12 , 14 . In this way, while plates 53 and grooves 55 are engaged, they provide for smooth and stable pivot as desired.
[0055] FIG. 15 illustrates an alternate embodiment wherein a screw 57 is used to pivotably secure arms 12 , 14 relative to each other.
[0056] FIG. 16 illustrates a still further alternate embodiment of the invention wherein a tapped rivet 58 is used to define pivot point 24 between arms 12 , 14 and also to manage the gap between the two arms in the z-direction. With this configuration, the box lock defined between the arms can be tightened as needed to reduce misalignment in the distal area.
[0057] FIGS. 17-22 illustrate a sequence of assembly of a surgical clip applier in accordance with the present invention. As shown in FIG. 17 , the assembly procedure can be started by aligning curved surfaces of a pivot point of a first arm 12 with corresponding surfaces on a second arm 14 . Once these surfaces are aligned, the arms 12 , 14 can be positioned together as illustrated by arrow D in FIG. 17 . This results in arms 12 , 14 being in the position shown in FIG. 18 . Arms 12 , 14 can then be pivoted toward each other such that the structure of pivot point 24 engages, and arms 12 , 14 are now held together.
[0058] FIGS. 23 and 23A show an alternate embodiment in a similar view to that illustrated in FIGS. 2 and 2A above. In these illustrations, jaws 30 are configured differently, and have more spring force built therein. Specifically, jaws 30 have inwardly arranged surfaces 60 which are positioned along inwardly bowed flexible prongs or arms 42 such that, when the applier is closed, portions 60 engage each other and outwardly flex prongs 42 . When the handles of the applier are released, the prongs or arms 42 bias the jaws back toward an open position.
[0059] In the embodiment as illustrated on FIGS. 23 and 23A , each of the prongs 42 comprise a knee defined giving the jaw a bent configuration at rest. Each knee is located between the jaw members 44 and a proximal part joining the two prongs to each other. Each knee protrudes towards the other prong. Each knee is adapted to biais a prong 42 toward its bent configuration whenever the prong is distorted into a shape different from its bent configuration. Knees may be arranged on prongs 42 so as to face each other. Each Knee may further have a curved surface facing the other knee.
[0060] When the applier is closed, the jaws are moved toward each other and at some point the knees come into contact with each other. When the applier is further closed, each bent prong is flexed by the other prong into into a more straightened configuration, and more precisely by the knee of the other prong. Thus, when the handles of the applier are released, the knees biais the straightened jaws toward their bent configuration. It should be understood that bent prongs provide a greater opening force that straight prongs such as these of the embodiment illustrated on FIGS. 4 to 6 . Nonetheless, the opening spring 50 may be combined with bent jaws in order to increase the opening force even more.
[0061] Although not illustrated, only one of the jaws may be bent at rest whereas the other jaw is straight. Besides, the knees may be formed in any other biaising member than the jaws.
[0062] A further alternative as illustrated in the embodiments of FIGS. 23 and 23A is that the structure supporting the pivot point of this embodiment is not positioned inside the jaws. Referring briefly, for example, to FIGS. 3 and 3A , it can be seen that pivot point is within a portion of the jaw component. In the embodiment of FIGS. 23 and 23A , rounded internal and external surfaces are incorporated into each of the arms 12 , 14 such that these surfaces 24 ′ engage one another when the arms are engaged, for example following the procedure shown in FIGS. 17-22 .
[0063] All other aspects of the embodiment of FIGS. 23 and 23 A are similar or identical to those discussed above.
[0064] The device illustrated herein has plates 53 and grooves 55 as shown in FIGS. 13-14 . Once pivot point 24 is engaged in the step shown in FIG. 17 to FIG. 18 , arms 12 , 14 can then be pivoted toward each other around pivot point 24 until plates 53 engage in grooves 55 at which point arms 12 , 14 are engaged with each other as shown in FIG. 19 .
[0065] Turning now to FIG. 20 , setting screw 32 can be rotated such that the maximum open position of arms 12 , 14 is adjusted. Next, jaws 30 are plugged into arms 12 , 14 , preferably into the space between distal portions 26 , 28 . At this point, applier 10 is now in condition for use as shown in FIG. 22 .
[0066] It should be appreciated that the present invention provides an applier for application of medical implants such as surgical clips and the like which is assembled as a scissor and which can, preferably, be permanently assembled or can be broken down into specific components as desired.
[0067] In addition, the jaw members can be made reposable so as to further enhance the efficient and effective sterile use of clip applier 10 in accordance with the present invention.
[0068] The maximum distal opening of the clip applier is readily adjustable through setting screw 32 .
[0069] Loops 20 of arms 12 , 14 can be provided with additional structures to render them more useful to manual operators, and this can for example include coatings and the like on the rings.
[0070] As best illustrated in FIG. 12 , once jaws 30 are released, cleaning is enhanced since water can enter and escape from surgical applier 10 via many areas, providing a good flushing flow. Further, there are no dead-ends in this new structure, which further helps to reduce any amount of dust which can adhere to the inside of the device.
[0071] It is to be understood that the invention is not limited to the illustrations described and shown herein, which are deemed to be merely illustrative of the best modes of carrying out the invention, and which are susceptible of modification of form, size, arrangement of parts and details of operation. The invention rather is intended to encompass all such modifications which are within its spirit and scope as defined by the claims.
|
A surgical clip applier comprises a first arm ( 12 ) and a second arm ( 14 ) pivotable relative to each other and defining proximal ends ( 16, 18 ) for manually controlling the applier, and distal ends ( 26, 28 ); jaws ( 30 ) positioned between the distal ends such ( 26, 28 ) that pivot of the first arm ( 12 ) relative to the second arm ( 14 ) opens and closes the jaws ( 30 ); and a setting element ( 32 ) movably mounted in one ( 12 ) of the first arm and the second arm and extending into contact with the other ( 14 ) of the first arm and the second arm to define a maximum open position of the first arm ( 12 ) relative to the second arm ( 14 ), and wherein a change of position of the setting element ( 32 ) adjusts the maximum open position.
| 0
|
[0001] This invention relates to a device for handling circular cylindrical tubular objects, with or without intervening bulges or flanges at their ends or intermediate their length. Furthermore it relates to a device that can grip such a tubular object not just for the purpose of lifting the object (in a direction including vertically upwardly in a direction parallel a longitudinal axis of the object), but also for the purpose of applying torque to the object about said longitudinal axis.
BACKGROUND
[0002] The drilling of subterranean wells involves assembling tubular strings, such as casing strings and drill strings, each of which comprises a plurality of heavy, elongated tubular segments extending downwardly from a drilling rig into a wellbore. The tubular string consists of a number of threadedly engaged tubular segments.
[0003] Conventionally, workers use a labor-intensive method to couple tubular segments to form a tubular string. This method involves the use of workers, typically a “stabber” and a tong operator. The stabber manually aligns the lower end of a tubular segment with the upper end of the existing tubular string, and the tong operator engages the tongs to rotate the segment, threadedly connecting it to the tubular string. While such a method is effective, it is dangerous, cumbersome and inefficient. Additionally, the tongs require multiple workers for proper engagement of the tubular segment and to couple the tubular segment to the tubular string. Thus, such a method is labour-intensive and therefore costly. Furthermore, using tongs can require the use of scaffolding or other like structures, which endangers workers.
[0004] Others have proposed a running tool utilizing a conventional top drive assembly for assembling tubular strings. The running tool includes a manipulator, which engages a tubular segment and raises the tubular segment up into a power assist elevator, which relies on applied energy to hold the tubular segment. The elevator couples to the top drive, which rotates the elevator. Thus, the tubular segment contacts a tubular string and the top drive rotates the tubular segment and threadedly engages it with the tubular string.
[0005] While such a tool provides benefits over the more conventional systems used to assemble tubular strings, it also suffers from shortcomings. One such shortcoming is that the tubular segment might be scarred by the elevator gripping dies. Another shortcoming is that a conventional manipulator arm cannot remove single joint tubulars and lay them down on the pipe deck without worker involvement.
[0006] Other tools have been proposed to cure these shortcomings. However, such tools are often unable to handle tubulars that are dimensionally non-uniform. When the tubulars being handled are not dimensionally ideal, such as by having a varying wall thickness or imperfect circularity of tube section, the ability of tools to adequately engage the tubulars is decreased.
[0007] There are many other circumstances in which it is desirable to handle other tubular objects. Indeed, the general handling of large pipe sections can be problematic, and a convenient tool for grabbing and loading pipes is desirable. Indeed, very large pipe sections (with a weight in the order of 6000 kN) are frequently provided with lifting and handling handles, but these generally require personnel to ensure appropriate hook up and disconnect. It would be desirable if a pipe could be provided with a simple mechanism for safe connection and disconnection of a lifting device that did not require human intervention at the site of connection. Of course, much smaller pipe sections might be provided with such lifting arrangements.
[0008] Floor slips are employed on production sites to hold casings and drill pipes being lowered into a well while a new length is connected to the top of the pipe or casing being held. An appropriate design of holder that did not need to open to allow flanges and the like on the casings and drill pipes to navigate through the floor slip, as well as not requiring human intervention in the immediate vicinity of the floor slip during holding and release operations, would be desirable.
[0009] Emergency disconnect packages are employed to connect rigid risers from subsea installations to surface vessels. Such vessels generally dynamically hold position above a riser but adverse weather conditions and sometimes an inability to maintain position require the possibility of an emergency disconnection from the riser. A device capable performing such function is desirable.
PRIOR ART
[0010] WO2008/085700 discloses a tubular handling apparatus, comprising: a slotted member having a plurality of elongated slots each extending in a direction; a recessed member slidably coupled to the slotted member and having a plurality of recesses each tapered in the direction from a shallow end to a deep end; and a plurality of rolling members each retained between one of the recesses and one of the slots; wherein each rolling member partially extends through the adjacent slot when located in the shallow end of the recess; and wherein each rolling member retracts within an outer perimeter of the slotted member when located in a deep end of the recess. Such apparatus is useful in gripping to both internal and external surfaces of tubulars. However, if the tubular has peripheral extensions then the slotted member cannot necessarily move over such extensions during positioning of the apparatus on the tubular.
[0011] WO2004/067854 discloses a tool for gripping a tubular object by contact with opposed surfaces thereof comprising a mandrel having means for attachment to lifting gear, at least one pair of gripping assemblies attached to the mandrel, each gripping assembly comprising a body member, a wedge member slidably movable on an individual ramp with respect to the body member towards and away from the mandrel, and a ball or roller cage slidably movable with respect to the wedge member and having at least one ball or roller movable with the ball or roller cage on an inclined ramp with respect to the wedge member thus to grip one of said opposed surfaces of the tubular object to be gripped. An annular array of such gripping assemblies may be attached to the mandrel, each with a wedge member and a ball or roller cage, such that each ball or roller is caused to make annular contact with the wall surface of the object of circular section. Such an arrangement is complex. Moreover, torque cannot be applied through the tool to the object gripped by it. However, it also discloses a plurality of arrays, one above the other.
[0012] US2005/0160881 discloses a clamping mechanism for applying torque, having two or more jaws that may be opened to allow a tubular to be introduced within the jaws and closed to retain the tubular therewithin. Rollers are located within concave recesses and maintained in spaced apart relationship by biasing means, whereby rotation of tubular may cause the rollers to be wedged between a wall of the recess and the tubular to grip the tubular within the jaws. The clamping mechanism may be utilized as an oil field tubular clamp, a slip, a pipe clamp, and other mechanisms. There is also disclosed a clutch comprising an outer race, a cage, and an inner ring. Recesses are provided in an outer race and accommodate rollers therewith and maintained in spaced apart relationship by the cage.
[0013] It is an object of the present invention to provide a relatively simple structure that is not only capable of lifting, but also of applying torque when desired.
[0014] It is another object to provide a device that is capable of permitting large diameter sections of tubular to pass through the device when it is in a release condition without it having to be opened and removed from the tubular.
[0015] It is a further object to provide a device that can be released rapidly from, and with less force than the clamping force applied by the device in, its locked condition.
SUMMARY OF THE INVENTION
[0016] In accordance with the present invention there is provided a gripping tool in the form of a body having a longitudinal axis and formed by a plurality of sleeves connected end to end, each sleeve including a frusto-conical bore centered on said longitudinal axis;
[0017] a clamp member in each sleeve formed by clamp-segments, each having side faces, end faces, a frusto-conical exterior surface adapted to match said frusto-conical bore, and a cylindrical interior surface;
[0018] cage-segments connected to said interior surface and having a plurality of windows partially closing recesses in said interior surface, which recesses are elongate in said longitudinal direction, house a roller and have a base inclined in said longitudinal direction so that, at a lower end of each recess the roller protrudes through said window and at an upper end thereof the roller protrudes less or not at all;
[0019] a bias mechanism, urging said clamp-segments apart from each other in a peripheral direction;
[0020] connection means between adjacent clamp segments so that they move together when one is moved axially.
[0021] Preferably, said connection means is a bolt passing longitudinally through all longitudinally aligned clamp-segments and clamping them together axially.
[0022] Preferably, a top one each of said clamp-segments has a lift eye by which said clamp elements may be lifted with respect to said sleeves so that said clamp-segments slide up said frusto-conical bore separating from one another in a peripheral direction as they progress.
[0023] Preferably, a key on one of said frusto-conical surfaces slides in a groove in the other of said frusto-conical surfaces whereby torque applied to said sleeves is transmitted to said clamp-segments. Preferably, said key and slot are parallel the cone angle of said frusto-conical surfaces.
[0024] Preferably, said key and slot are central in said clamp-segment between said side faces. Preferably, there are three clamp-segments.
[0025] Preferably, said side faces are planar and disposed in radial planes with respect to said longitudinal axis. Preferably, between a clamp position and an open position of the tool, the segments move from position in which the arcs of the cage segments lie in a common cylindrical surface and the frusto-conical surfaces are flush with each other, to a release position in which said side faces are spaced from one another and said frustoconical surfaces have only line contact between them.
[0026] Alternatively, said frusto-conical surfaces are inclined part-cylindrical surfaces.
[0027] Preferably, said sleeves are seated in a hollow housing tube. The tube and sleeves may have between them a key whereby torque applied to the housing is transmitted to said sleeves. Said housing may have a cylindrical bore with an internal ledge at its bottom end, said sleeves being loaded from a top end, a bottom one seating on said ledge and succeeding ones seating on the one below.
[0028] Preferably, said rollers are balls and said recesses have a semi-circular base of diameter substantially equal to the diameter of the balls.
[0029] Preferably, said bias mechanism comprises a spring between each facing side face of adjacent clamp-segments.
[0030] Thus, when said lifting eyes are each attached to a lifting cable that lifts the clamp segments, the segments separate sufficiently to release any tubular clamped between the clamp-segments. That is to say, preferably the angle of inclination with respect to the longitudinal axis of the frusto-conical surfaces is greater than the angle of inclination of the recess bases. The latter is preferably between 3 and 10 degrees, preferably between 5 and 8 degrees. The former is preferably between 10 and 20 degrees, and more preferably between 13 and 16 degrees.
[0031] Preferably, the tool is designed to clamp on tubular members whose diameter is such that, when the clamp-segments abut one another with mating side faces and the frustoconical surfaces are also mating, the rollers when they evenly contact the tubular are nearer the top end of the recess than the bottom. This provides maximum tolerance while still maintaining the strongest connections between the clamp-segments and sleeves. Of course, should the tubular be larger then it is possible that the rollers may be at the top of their recesses in contact with the tubular and yet the clamp-segments are not in mating contact side face to side face. This is still acceptable since the segments are wedged firmed between the mating cylindrical surfaces of the tubular and their interior surfaces and frusto-conical surfaces (in fact preferably inclined cylindrical) surfaces of the exterior surface of the clamp-segments and the bores of the sleeves.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] The present disclosure is best understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.
[0033] FIGS. 1 a, b and c are respectively, a cutaway perspective view of a two-sleeve gripping tool in accordance with the present invention, a tubular housing, and an exploded view of the tool of FIG. 1 a;
[0034] FIG. 2 is a side section illustrating general principle of operation of a tool according to the present invention;
[0035] FIG. 3 is an exploded side view of a clamp segment and assembled view of two others forming a partially complete clamp member used in another embodiment of the present invention;
[0036] FIGS. 4 a and b are side sections of a four-sleeve gripping tool using the clamp members of FIG. 3 , FIG. 4 a showing the tool in its closed or clamping position and FIG. 4 b showing the tool open;
[0037] FIG. 5 is a perspective cutaway view of the tool of FIGS. 4 a and b ; and
[0038] FIG. 6 is a side section illustrating a size benefit of a tool according to the present invention.
DETAILED DESCRIPTION
[0039] It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact.
[0040] Referring to FIGS. 1 a to c , illustrated are perspective views of at least a portion of an apparatus 100 according to one or more aspects of the present disclosure. The tool 100 comprises a tubular housing 110 .
[0041] Tool 100 is configured to receive and at least temporarily grip, frictionally engage, or otherwise retain a tubular member 105 (shown in FIG. 2 ). For example, the tool 100 may be configured to grip or otherwise frictionally engage an exterior surface of the tubular member 105 . The extent to which the tool 100 engages the tubular member 105 may be sufficient to support a safe working load (SWL) of at least 5 tons. However, other SWL values for the tool 100 are also within the scope of the present disclosure.
[0042] Furthermore, the extent to which the tool 100 engages the tubular member 105 may also be sufficient to impart a torsional force to the tubular member 105 , such as may be transmitted through a running tool (not shown) from a top drive or other component of a drill string (also not shown). In an exemplary embodiment, the torque which may be applied to the tubular member 105 via the tool 100 may be at least about 6700 Nm (about 5000 ft-lbs), which may be sufficient to “make-up” a connection between the tubular member 105 and another tubular member. The torque which may be applied to the tubular member 105 may additionally or alternatively be at least about 67,000 Nm (about 50,000 ft-lbs), which may be sufficient to “break” a connection between the tubular member 105 and another tubular member. However, other torque values are also within the scope of the present disclosure.
[0043] The tubular member in question may be a wellbore casing member, a drill string tubing member, a pipe member, a collared tubing member, and/or other tubular elements. The tubular member 105 may be a single tubular section, or pre-assembled double or triple sections. The tubular member 105 may be or comprise a section of a pipeline, such as may be utilized in the transport of liquid and/or fluid materials. The tubular member 105 may alternatively be or comprise one or more other tubular structural members. The tubular member may have an annulus cross-section having a substantially circular cylindrical shape, although approximations thereof may be engaged.
[0044] The tubular member 105 may not be dimensionally uniform or otherwise ideal. That is, the tubular member may not exhibit ideal roundness or circularity, such that all of the points on an outer surface of the tubular member 105 at a certain axial position may not form a perfect circle. Alternatively, or additionally, the tubular member 105 may not exhibit ideal cylindricity, such that all of the points of the outer surface may not be equidistant from a longitudinal axis 202 of the tool 100 , and/or the tubular member 105 may not exhibit ideal concentricity, such that the axes of all cross sectional elements of the outer surface may not be common to the longitudinal axis 202 .
[0045] Referring to FIG. 2 , illustrated is a sectional view of at least a portion of an exemplary embodiment of a clamping member 700 of the tool 100 about a tubular member 105 . The clamping member 700 includes a recessed member 210 , a slotted or otherwise perforated cage member 220 , and a plurality of rolling members 230 .
[0046] The recessed member 210 is substantially cylindrical when formed, having a plurality of recesses 214 therein. The cage member 220 is typically slotted with windows 222 but is not limited to such a configuration. The cage member 220 is fixed to the recessed member 210 , preferably by screws (not shown, although see screws 501 in FIG. 5 ). Each slot or window 222 is configured to cooperate with one of the recesses 214 of the recessed member 210 to retain one of the rolling members 230 . Moreover, each recess 214 and slot 222 is configured such that, when a rolling member 230 is moved further away from the maximum depth 214 a of the recess 214 (that is, to a lower end 232 of the recess), the rolling member 230 protrudes further through the slot 222 and beyond an inner perimeter 224 of the slotted member 220 , and when the rolling member 230 is moved towards the maximum depth 214 a of the recess 214 (that is, to an upper end 234 ), the rolling member 230 also moves towards a retracted position within the inner perimeter 224 of the slotted member 220 . That is to say, the bases 236 of the recesses are inclined with respect to the longitudinal axis 202 and are inclined inwardly and downwardly with respect to the normal orientation of the tool in use (which is as shown in FIG. 2 ).
[0047] Each slot 222 may have an oval or otherwise elongated profile, such that each slot 222 is greater in length than in width. The length of the slot 222 is in the direction of the longitudinal axis 202 of the tool 100 . The walls of each slot 222 may be tapered radially inwardly.
[0048] Each recess 214 may have a width (into the page in FIG. 2 ) that is at least about equal to or slightly larger than the width or diameter of each rolling member 230 . Each recess 214 may also have a length that is greater than a minimum length of the slot 222 . The width or diameter of the rolling member 230 is at least larger than the width of the internal profile of the slot 222 .
[0049] Because each slot 222 is elongated in the direction of the taper of the recesses 214 , each rolling member 230 may protrude from the slotted member 220 an independent amount based on the proximate dimensional characteristics of the tubular member 105 . For example, if the outer diameter of the tubular member 105 is smaller near the end 105 a of the tubular member 105 , the rolling member 230 located nearest the end 105 a of the tubular member 105 protrudes from the slotted member 220 a greater distance relative to the distance which the rolling member 230 nearest the central portion of the tubular member 105 protrudes from the slotted member 220 .
[0050] Each of the rolling members 230 may be or comprise a substantially spherical member, such as a steel ball bearing. However, other materials and shapes are also within the scope of the present disclosure. For example, each of the rolling members 230 may alternatively be a cylindrical or tapered pin configured to roll up and down the ramps defined by the recesses 214 .
[0051] Referring to FIG. 3 , illustrated is an exploded perspective view of the clamping member 700 of FIG. 2 . From FIG. 3 , it can be seen that the clamping member 700 actually comprises (in this embodiment) three clamping segments 700 a,b,c , segment 700 a of which is shown exploded and separated from the other two. From this it can also be seen that the slotted cage member 220 and recessed member 210 are likewise each in three segments.
[0052] The tool 100 also includes a holder 740 which also comprises three discrete sections 740 a,b,c . Other functionally equivalent configurations may combine holders 740 a,b,c and recessed member 210 a,b,c to create an integral member in each case. Each holder section 740 a,b,c may include a flange 745 configured to be coupled with a flange 745 of another of the holder sections 740 a,b,c , such that the holder sections 740 a,b,c may be assembled to form a bowl-type structure configured to hold the recessed sections 210 a,b,c of the recessed member 210 , as well as sections 220 , and the rolling members 230 .
[0053] FIGS. 4A and 4B are side sectional views of the clamping member 700 shown in FIG. 3 in engaged and disengaged positions, respectively. Referring to FIGS. 4A and 4B collectively, with continued reference to FIG. 3 , the tool 100 includes multiple clamping members 700 stacked vertically. Hereinafter, the clamping members 700 may also be referred to as vertical segments to reflect their vertically stacked arrangement. In the exemplary embodiment shown in FIGS. 4A and 4B , the apparatus 100 includes four vertical segments 700 . In other embodiments, however, the apparatus may include fewer or more segments. The gripping force applied by the apparatus to the tubular member is at least partially proportional to the number of vertical segments (clamping members) 700 , such that increasing the number of segments 700 increases the lifting capacity of the apparatus 100 , as well as the torque which may be applied to the tubular member by the apparatus. Each of the vertical segments 700 may be substantially similar or identical, although the top and bottom segments 700 may have unique interfaces for coupling with additional equipment between a top drive (not shown), for instance, and the casing string. Indeed, bottom clamping member 700 d is shown with an additional skirt 760 to receive bottom holder 740 d , as described further below.
[0054] The external profile of each holder 740 is tapered at 770 in a frusto-conical fashion, (although, preferably, the frusto-cone is the special case of a circular cylinder and, instead, the axis of the cylindrical surface 770 is merely inclined towards (and so as to intersect) the longitudinal axis 202 of the tool), such that the lower end of each holder 740 has a smaller diameter than its upper end. Each vertical segment 700 of the apparatus 100 also includes a tubular housing sleeve 750 having an internal profile configured to cooperate with the external profile 770 of the holder 740 such that as the holder 740 moves downward (relative to the housing sleeve 750 ) towards the engaged, clamping, position ( FIG. 4 a ) the holder 740 constricts radially inward. Yet, when the holder 740 moves upward, towards the disengaged position ( FIG. 4 b ) the holder 740 expands radially outward.
[0055] The top segment 700 a of the apparatus 100 may include an interface (hook eye) 760 configured to couple with one or more hydraulic cylinders and/or other actuators (not shown). Moreover, each holder 740 is coupled to its upper and lower neighboring holders 740 . Consequently, vertical movement urged by the one or more actuators coupled to the interface 760 results in simultaneous vertical movement of all of the holders 740 . Accordingly, downward movement of the holders 740 driven by the one or more actuators causes the rolling members 230 to engage the outer surface of the tubular member 105 , whereas upward movement of the holders 740 driven by the one or more actuators causes the rolling members 230 to disengage the tubular member 105 . The force applied by the one or more actuators to drive the downward movement of the holders 740 to engage the rolling members 230 with the tubular member 105 is one example of a preload that can be applied in order to pre-grip the tubular member 105 if gravity is not available to press the holder downwardly.
[0056] Referring back, now, to FIGS. 1 a, b and c , tool 100 is a two-section tool, having two clamping members 700 d,e vertically aligned. Tubular housing 110 here comprises a simple tube having a bottom internal flange 152 on which external flange 154 of bottom housing 750 d seats. Bottom flange 156 of top housing 750 e seats on top edge 158 of bottom housing 750 d . A key 170 is fixed internally of the housing 110 by bolts 171 and slides in axially extending slots 172 on the outside of the housing sleeves 750 d,e . Torque can then be transmitted by the housing 110 to the sleeves 750 d,e.
[0057] Each vertically aligned holder 740 is interconnected by a pair of bolts 160 . A spacer 162 and spring 164 being disposed between them and the connection being completed by a lock nut 166 that, when tightened, permits some relative vertical movement between holders 740 . The purpose of this is to permit each clamping member 700 d,e to independently clamp on the tubular member 105 .
[0058] In use, tubular member 105 is inserted from underneath the tool 100 . Prior to this, the holders 740 have been lowered into the tubular housing 110 and sleeves 750 d,e so that they collapse inwardly to the clamping position depicted in FIG. 4 a where radial faces 168 of adjacent holder sections 740 a,b,c abut one another. In this position, the cage members 220 and internal face of the holders 740 (which here constitute also the recessed member 210 of FIG. 3 described above) are essentially on surfaces of the same cylinder. This cylinder coincides with the design cylinder of tubular members 105 the tool is intended to handle. However, when inserted from underneath, the tubular may not be absolutely true. Indeed, the internal frusto-conical surfaces of the housing sleeves 750 d,e or the corresponding external surfaces 770 of the holders 740 might exhibit some tolerance. Finally, the pickup by the rollers 230 may also show some variation. These differences are to some extent accommodated and shared between the two clamp members 700 d,e when a small freedom of movement between them is permitted, as provided by the bolts 160 . Thus, when inserted from underneath and then the tubular housing 110 is lifted, the rollers 230 progressively bite into the tubular member 105 . Some rollers 230 may not bite to the same extent as others, and the partial separation of the holders 740 permits some tolerance to be accommodated.
[0059] The holders have said frusto-conical external surfaces 770 , as described above. These mate with corresponding frusto-conical internal surfaces 752 of the housing sleeves 750 . The surfaces 770 include keys 742 that fit in slots 754 in the housing sleeves 750 . If the surfaces 770 , 752 are truly conical, then they only mate in area contact in one axial position, which is arranged to be when the radial faces 168 of the holder sections 740 a,b,c abut. In this event, as the holders 740 rise up, only a line contact remains between the surfaces 770 , 752 . Accordingly, it is preferred, as stated above, that the engaging surfaces 770 , 752 are inclined cylindrical surfaces, in which event there is area contact in all axial positions. However, since there is only load applied when the holders 740 are in their clamp position, it is not a significantly important point. However, the keys 742 are preferably central in each holder 740 . The keys 742 transmit torque between the housing sleeves 750 and the holders 740 .
[0060] When a tubular member 105 is to be released by the tool 100 , the weight of the tubular member 105 is taken from the tool 100 by other means (not shown). These means may simply comprise the tubular member 105 reaching a limit of travel after being lowered into a well bore. Alternatively, such means may comprise a floor slip arrangement (that may itself take the form of a tool according to the present invention). When the weight has been released, the holders 740 are lifted within the housing sleeve 750 . When the holders 740 rise relative to the housing sleeves 750 , springs 780 press the radial faces 168 apart. The tapered surfaces 770 , 752 of the holders 740 and housing sleeves 750 allow the clamp segments to spread significantly, whereby not only is the tubular member 105 released, but also enlargements that may be in the tubular member 105 can pass through the tool 100 . This is frequently the case in drill strings where connections between adjoining drill pipe sections may have an enlarged diameter.
[0061] The taper on the surfaces 770 , 752 is preferably about 15 degrees with respect to the longitudinal axis 202 . Although shown much greater in FIG. 2 , the inclination of the bases of the recesses 214 to the longitudinal axis is only about 10 degrees. The effect of this is that lifting the holders 740 immediately releases the clamping pressure without requiring significant force. Indeed, the arrangement is such that, in some applications, it is unnecessary to relieve the load of the tubular member 105 before releasing the tool 100 . Such may be required in emergency situations. Indeed, umbilical connections between undersea installations and surface vessels often must be suddenly released and the present arrangement provides this capacity.
[0062] An advantage provided by dividing the clamping members 700 into short vertical sections is that the inclined surface needed to support a sufficiently long axial length for the holders 740 to attain sufficient grip on the tubular member 105 for the loads being envisaged can be provided in a relatively restrained diameter. FIG. 6 illustrates the profile 600 that a single vertical section tool would need to have if it were to have the same gripping power of a twin-section tool 100 as shown in FIGS. 1 a,b and c . This is achieved simply by extending the taper 602 of the lower section as it would need to proceed if only a single clamp section was employed. Not only would this increase the dimensions of the tool (from diameter d to D in FIG. 6 ) but also the mass of the tool would commensurately be increased. Indeed, by constructing the housing from several components (the tubular housing 110 and housing sleeves 750 ) a particularly compact design is achieved, and one that is relatively easy to manufacture since there are few undercuts to be made.
[0063] Each holder section 740 a,b,c therefore has said frusto-conical external surface 770 (within the meaning of which is included inclined cylindrical or other approximation thereof) radial faces 168 (which in the arrangements illustrated are in radial planes, but this is not essential—therefore, the radial faces 168 may also be referred to as side faces) abutting end faces (see top face 743 in FIGS. 1 a and c on which said lifting eyes 760 are fixed) and cylindrical and recessed internal face 746 (not visible except in FIGS. 2 and 3 ), which may be constituted in a separate component 210 .
[0064] The foregoing outlines features of several embodiments so that those skilled in the art may better understand the aspects of the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions and alterations herein without departing from the scope of the present disclosure.
[0065] For example, embodiments of the invention, with suitable adaptation that would be evident to the person skilled in the art, have applications not limited to floor slips, handling apparatus and emergency disconnect devices.
[0066] In the case of floor slips, for example, the release of the tubular is easily and quickly effected by lifting the clamping members within the tubular housing sleeve. The spread of the individual segments on such lifting opens the aperture through the tool so that bulges and other flanges on the drill pipe or casing being controlled by the floor slip can pass through the tool without the need to open the tool and remove it laterally from the tubular.
[0067] In the case of handling equipment generally, or specifically for large pipe sections, for example, a simple tube or rod can be provided as a handle to be gripped by the tool of the present invention. Indeed, a flange can be disposed on the end of the handle in the event that the grip of the tool should falter or fail and whereby the flange will catch on the upper surface of the holder and press it into tighter engagement with the handle. In the locked position of the holder, the flange would be unable to pass through the tool, whereby a safety mechanism is provided. However, when the tool is released in normal operation by the holder being lifted in the housing sleeve, the spread of the clamping members opens the passage between them so that the flange on the handle could be accommodated to effect normal release (and engagement) of the tool from (and with) the handle.
[0068] In the case of emergency disconnect packages, the force needed to lift the holder is much less than the clamping force effect by the holder on the tubular it is gripping, whereby rapid disconnection is facilitated.
[0069] Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to”, and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.
[0070] Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
[0071] The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.
REFERENCE NUMERALS
[0000]
100 —tool capable of lifting and applying torque
105 —tubular abutment/tubular member
105 a —end of tubular member 105
110 —tubular housing (of tool 100 )
152 —bottom internal flange (of tubular housing 110 )
154 —external flange (of bottom housing 750 d )
156 —bottom flange (of top housing 750 e )
158 —top edge (of top housing 750 e )
160 —bolts (used in connecting vertically aligned holders 740 )
162 —spacer (used in connecting vertically aligned holders 740 )
164 —spring (used in connecting vertically aligned holders 740 )
166 —lock nut (used in connecting vertically aligned holders 740 )
168 —radial or side faces (of adjacent aligned holders 740 )
170 —key (of tubular housing 110 )
171 —bolts (affixing key 170 to tubular housing 110 )
172 —axially extending slots (on outside of housing sleeves 750 d,e )
202 —longitudinal axis (of tool 100 )
210 —recessed member (of clamping member 700 )
210 a,b,c —individual segments of recessed member 210
214 —recesses (of recessed member 210 )
214 a —maximum depth of recesses 214
220 —(slotted or otherwise) cage member (of clamping member 700 )
222 —windows/slots (of cage member 220 )
224 —perimeter of slotted member 220
230 —rolling members (of clamping member 700 )
232 —lower ends of recesses 214
234 —upper ends of recesses 214
236 —bases of recesses 214
501 —screws (fixing cage member 220 to recessed member 210 )
700 —clamping member/vertical segments
700 a,b,c —individual segments of clamping member 700
700 d —bottom clamping member/vertical segment
740 —holder (of tool 100 )
740 a,b,c —discrete sections of holder 740
742 —keys (of external surfaces 741 of holders 740 )
743 —top face or abutting end face of (top) holder 740
745 —flange of each section 740 a,b,c of holder 740
750 —tubular housing sleeve (of each vertical segment 700 )
750 d —bottom tubular housing sleeve
750 e —top tubular housing sleeve
752 —frusto-conical external surfaces (of holders 740 )
754 —keys (of external surfaces 741 of holders 740 )
760 —skirt (of bottom clamping member 700 d )
770 —tapered, cylindrical, external profile (of each holder 740 )
780 —springs (that press radial faces 168 apart)
|
A tubular member handling apparatus is a gripping tool ( 100 ) in the form of a body ( 110 ) having a longitudinal axis ( 202 ) and formed by a plurality of sleeves ( 750 ) connected end to end, each sleeve including a frusto-conical bore 752 centered on said longitudinal axis; a clamp member ( 700 ) in each sleeve formed by clamp-segments ( 740 ), each having side faces ( 168 ), end faces ( 743 ), a frusto-conical exterior surface ( 741 ) adapted to match said frusto-conical bore, and a cylindrical interior surface ( 745 ); cage-segments ( 220 ) connected to said interior surface and having a plurality of windows ( 222 ) partially closing recesses ( 214 ) in said interior surface, which recesses are elongate in said longitudinal direction, house a roller ( 230 ) and have a base ( 236 ) inclined in said longitudinal direction so that, at a lower end ( 232 ) of each recess the roller protrudes through said window and at an upper end ( 234 ) thereof the roller protrudes less or not at all; a bias mechanism 780 , urging said clamp-segments apart from each other in a peripheral direction; connection means ( 160 ) between adjacent clamp segments so that they move together when one is moved axially.
| 4
|
BACKGROUND OF THE INVENTION
The present invention relates to a multiple cylinder dryer of a paper machine. More particularly, the invention relates to an air-directing device for a multiple cylinder dryer of a paper machine, which device introduces air to the dryer and includes air-blowing members.
Regarding the technology associated with the invention, reference is made to SE patent No. 67,305, SE patent No. 321,408, CA patent No. 810,896, U.S. Pat. No. 3,283,415, British Pat. No. 927,564 and FI patent No. 45,884.
The present invention touches on the procedure in a multiple cylinder dryer disclosed in Finnish patent application No. 803,720 of the inventor which issued as Finnish Pat. No. 62,693 on Feb. 10, 1983, wherein the dryer comprises a number of heatable cylinders and potentially equivalent rollers. A drying fabric is used in the dryer in support of which drying fabric a web goes from one cylinder and/or roller to another in closed conduction. The cyclic travel of the fabric is so arranged that part of the drying cylinders and/or rollers remain within the loop of the fabric and part thereof outside the loop. One or more supporting fabrics are used in the dryer to carry the web on the cylinders and/or rollers. The supporting fabric are guided by guide rollers. In the dryer, elongated pockets are defined in conjunction with the cylinders by the web runs supported by the drying fabric, by the free surfaces of the drying cylinders and by the runs of the supporting fabric.
The aforedescribed procedure disclosed in said Finnish patent application is mainly characterized in that of the aforementioned pockets in which the web resides on that side of the fabric which faces the pocket have been rendered under atmospheric pressure, at least in the initial part of the dryer, as viewed in the direction of travel of the web, and under a pressure higher than in the adjacent pockets, so that the differential pressure in question will urge the web against the felt with a view to stabilizing the running of the web.
It is known in the art to utilize various types of air conditioning apparatus, blow tubes, etc. in the drying section of a paper machine. These have been used in connection with twin-wire conduction for regulating the humidity of air in the pockets. They influence the pressure level in certain instances, but since this influence is not directional in any way, and since the pressure level is the same in the pockets on both sides of the web, it has not been possible thereby to effect the behavior of the web. As known in the art, more modern apparatus of this type have been located on the non-paper side of the felts, and the older apparatus, when actual felts are used, have been located on the paper side of the fabric or at the ends of the pockets.
In connection with single felt conduction, as known in the art, no actual pocket ventilating devices have been used, as a rule. Replacement air has in some instances been introduced from below the single felt conduction drying section by header beams extending across the machine and usually disposed in the interstices of the transversal structural beams of the building. The structural designs have recently been altered in such a way that the beams are completely omitted. For this reason, separate air introduction tubes are no longer permitted under a single felt drying section. Such tubes might break in the event of a web break. It has not been possible by this procedure to promote web stability.
Blowing from the side in, under the machine, has been utilized in connection with single felt conduction for the purpose of supplying replacement air. The pressure level and the behavior of the web, in the sense implied in the invention, could not be influenced by this expedient, either. On the contrary, this procedure of the prior art has caused instability of the web, particularly in the marginal part.
Although the air-directing device of the invention is primarily intended to be used in connection with single felt conduction, it is appropriate for use more universally.
SUMMARY OF THE INVENTION
The principal object of the invention is to provide an air-directing device for a multiple cylinder dryer of a paper machine, which device serves as introduction passages for air absolutely required in view of the air flow balance in the region in question, which passages direct dry air to the vicinity of the web, at these points where the evaporation of water from the web is strongest, whereby the humidity in the region may be reduced, thereby promoting the evaporation of water from the web.
An object of the invention is to provide an air-directing device for a multiple cylinder dryer of a paper machine, which device directs dry air to points which are the initial parts of the cylinder intervals after contact with the web.
Another object of the invention is to provide an air-directing device for a multiple cylinder dryer of a paper machine, which device functions economically, efficiently, effectively and reliably to direct air into the clefts defined by the surface of the drying cylinder and the paper web.
In order to attain these objects, and others which will become apparent hereinafter, in accordance with the invention, the air-directing device is so placed, and its air-blowing members are so disposed and directed, that the air blown out from such members is directed into the clefts defined by the surface of the drying cylinder and the paper web and achieves a pressure effect in the clefts.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the invention, reference is had to the following description, taken in connection with the accompanying drawings, in which:
FIG. 1 is a schematic diagram of a multiple cylinder dryer of a paper machine, showing the placing of the air-directing devices of the invention;
FIG. 2 is a schematic diagram of an embodiment of an air circuit system for the air-directing device of the invention;
FIG. 3 is a sectional view, on an enlarged scale, of an embodiment of the air-directing device and a first embodiment of the air-blowing member of the invention, showing the placing thereof in a multiple cylinder dryer of a paper machine;
FIG. 3A is a sectional view, on an enlarged scale, of the embodiment of the air-blowing member of FIG. 3;
FIG. 3B is a bottom view, on an enlarged scale, of the embodiment of FIG. 3A, taken along the lines IIIB--IIIB, of FIG. 3A;
FIG. 4 is a sectional view, on a greatly enlarged scale, of part of a second embodiment of the air-blowing member of the device of the invention;
FIG. 4A is a sectional view, on a greatly enlarged scale, of part of a third embodiment of the air-blowing member of the device of the invention;
FIG. 5 is a schematic diagram, on an enlarged scale, of an embodiment of a connecting device connecting the doctor to the air-directing device of the invention; and
FIG. 6 is a schematic diagram, on an enlarged scale, of an embodiment of the air-blowing member of the air-directing device of the invention, showing air-blowing directions in marginal areas of the doctor blade and web.
DESCRIPTION OF PREFERRED EMBODIMENTS
The multiple cylinder dryer depicted in FIG. 1 comprises two rows of drying cylinders one above the other. These consist of a row of upper cylinders 1 and a row of lower cylinders 2. Single felt conduction is implemented in the initial part of the group of cylinders 1 and 2, using a drying fabric 3, such as, for example, felt, in support of which the paper web W runs in zigzag fashion from one row of cylinders to the other. The path of the drying fabric 3 changes under the guidance of guide rollers 7 after the second cylinder in the upper row, so that the web has free draws W P between the cylinders 1 and 2. Guide rollers 6 are provided in the interstices of the lower cylinders 2. A supporting fabric 3', which carries the web W on the cylinders 2, passes over said guide rollers. A similar supporting fabric may also be provided in conjunction with the first cylinders 1.
Beams 4, 4' and 4" are provided in conjunction with the free surfaces of the upper cylinders 1. The beam 4' simultaneously serves as a frame for the doctor blade. In accordance with the invention, the box-type beams 4, 4' and 4" are used as headers to conduct and direct air into pockets P and into clefts 13 and 14, or cleft 13.
FIG. 1 shows three alternative placements of the air-blowing members or beams 4, 4' and 4" of the invention, as well as the preferred blowing directions F 1 and F 2 of said members. In twin felt conduction, the velocities of the air blown in the directions F 1 and F 2 should be kept comparatively low. The desired air flow must be produced primarily by a wide flow cross-sectional area. In single felt conduction, by contrast, considerable over-pressures and differential pressures with reference to the ambient atmospheric pressure P o may be achieved.
In FIG. 1, the air flow F 2 induced by the felt 3 at A 1 tends to pass through said felt. Sub-atmospheric pressure is in the cleft 13 on the side where the web W is. Due to the combined effect of the air flow and the sub-atmospheric pressure, the web W tends to separate from the felt 3, whereby the support action of said felt stabilizing said web and reducing the web breaks would be lost. On the other hand, the small air quantities which are captured in the cleft 14 between the web W and the felt 3 cause an over-pressure in said cleft. If this over-pressure does not have time to discharge through the felt 3, a bulge is formed in the web W in the cleft 14, as shown by broken lines in FIG. 1, and this causes wrinkles in said web and even web breaks.
As hereinbefore mentioned, no influence could be exerted on the aforedescribed phenomena by the known or traditional procedures, because even when potentially affecting the pressure level, these methods merely raise the pressure level on the whole. This produces no differential pressure across the web, which is the object of the invention, achieved by directing to critical points the pressure effect produced by a pulse of air flow.
In trial machine experiments carried out by the inventor, pressures up to 550 Pa have been measured, under operating conditions of air blown in the directions F 1 and F 2 at the sides of the web W. In the absence of extra equipment, there is a sub-atmospheric pressure of about 10 to 20 Pa at the side of the web W in the region A 1 . Correspondingly, there is a slight over-pressure in the region A 2 , depending on the machine speed. Measurements performed by the inventor in actual practice, on production machines, indicate that substantially lower differential pressures have a significant effect on the behavior of the web W in the critical regions discussed.
The air-blowing operations of the air-directing device of the invention thus make it easy to produce an over-pressure which cancels the pressures tending to detach the web W from the felt 3, on the side of said web.
FIG. 2 shows a system for connecting a doctor blade in accordance with the invention, which enables volumetric flows to be used for blowing air which exceed the replacement air quantity consistent with the air flow balance. In FIG. 2, a pipe 20 communicates with the network supplying the pocket ventilation and/or replacement air (not shown in the FIGS.). The flow to the air-blowing members 4, 4' and 4" is controlled by a valve 17'. A pipe system 16 begins inside the hood at a filter 18 and continues to a blower 19, which may be a controllable output blower. The pipe system 16 continues from the blower 19 through control valves 17" and 17 to a branch point 22, whence it continues as a single pipe 23 to the air-blowing members 4, 4' and 4".
FIGS. 3, 3A and 3B show the blowing of air in the direction F 2 towards the cleft 13. The most critical region is in the cleft 13 immediately after the felt 3 and web W separate from the cylinder 1. It has been found in trial machine experiments carried out by the inventor that the optimum direction of the blowing of air in the direction F 1 is that which causes the main direction of the jet to strike the cylinder 1 immediately before the point where the web W separates from said cylinder.
FIG. 3A shows details of the air-blowing member 4 of FIG. 3 and illustrates a first way of guiding the air flow in the aforedescribed manner.
FIG. 3B is a bottom view of the embodiment of FIG. 3A. The air-blowing member 4 of FIG. 3B may be referred to as a doctor or blowing doctor while simultaneously serving as a doctor beam. The member 4 of FIG. 3B includes a doctor blade 26, apertures or holes 27 formed through said member for blowing out air, a guide baffle 24, a blade holder 25, and, in the marginal areas, a control mechanism for adjustment of the flow of air through the outflow holes or apertures. The control mechanism of FIG. 3B, which is not indispensable, is shown as a slide mechanism, with a perforated slide 29 and holders 29'. The control system may be provided on one or both margins of the doctor 4. The same function may also be accomplished by increasing the distance x of the first outflow aperture from the edge of the web W, and/or by escalating the aperture spacing x' so that it is wider on the margins, and/or by restricting the flow of air through the apertures closest to the edge.
In FIG. 3B, a pipe or duct 28 directs air into the air-blowing member or doctor 4. The foregoing applies to the breadth direction of the flow direction F 1 , but the flow is directed into the cleft 14 by the effect of the state of motion of the surroundings, which are the cylinder 2 and the web W, provided that it is initially blown obliquely along with the direction of travel of said web.
FIG. 3B is a slide mechanism, in which there is a perforated slide 29 in holders. The control of air quantity is carried out by moving the slide 29 in longitudinal direction and, for example, in the axial direction of the cylinder 1, so that the area of the parts of the holes 27 and 29 through which air may flow, and which are in alignment or partial alignment with each other, may be controlled. When the holes 27 and 29 are located exactly in alignment with each other, restriction is smallest and air quantity is greatest. On the other hand, the slide 29 may be moved to such a position that the hole 27 and the slide holes have no common area, whereby the control device is in a fully-closed position.
FIGS. 4 and 4A show second and third embodiments of the air-blowing member or doctor 4' and 4", respectively. The embodiments of FIGS. 4 and 4A blow air in the direction F 2 to direct it into the cleft 13. The embodiment of FIG. 4 is based on the principle that an air flow blown along a surface 30 follows said surface due to the Coanda effect, if the angle subtended by the blowing action with said surface and the curvature and blowing velocity have an appropriate ratio. In directing the air flow, as shown in FIG. 4, it must be taken into consideration that the blown air jet F 2 fans out. There thus remains between the trailing part of the guiding surface and the desired jet an angle α≈5° to 15°. This must be taken into account when determining the shape of the directing or guiding surface 30.
In the embodiment of FIG. 4A, a guide baffle 31 directs the air flow F 2 . The baffle 31 deflects the air flow in the desired direction F 2 and ejects an air flow F e along with itself, in a space 32, with particular efficiency.
FIG. 5 shows additional components of the air-directing device of the invention for supplying air to the air-blowing member or doctor 4 or 4' of the invention. Since the doctor 4 or 4' normally oscillates axially and it should be possible to lift off its blade 26 by turning the doctor beam about its longitudinal axis, the air-directing device of the invention must be so arranged that these operations are feasible.
The pipe required to conduct the requisite air quantities must have a diameter so large that it is doubtful whether a flexible junction or bellows can be provided which provides continuous satisfactory service under the conditions present in the machine hood. This problem may be circumvented by the system shown in FIG. 5. In FIG. 5, a pipe or tube 44 is connected to the blowing air supply system or network (not shown in the Figs.) and is fixedly mounted on the machine frame. Another pipe or tube 45 is integrally mounted in conjunction with a connector 39 of the doctor 4. The tube 45 is able to swivel around the bearings 38 of the doctor 4, which bearings are designed to also permit the axial movement of said doctor.
The tube 45 has a reduced diameter socket 40 which fits over a reduced diameter socket 41 of the pipe 44. The pipe 44 also has a collar 42 which fits over the reduced diameter socket 40 of the tube 45. The reduced diameter sockets 40 and 41 and the collar 42 are round and are installed so that the socket 40 will in no position touch the socket 41 of said collar. Instead, there is a radial clearance between the sockets 40 and 41. The clearance is preferably about 1 to 5 mm. Leakage through the radial gap between the sockets 40 and 41 is prevented by the special design of the structural component and by so dimensioning the diameters that P 2 =P o =atmospheric pressure. The meaning of the pressure notations P 1 and P 2 is clearly indicated in FIG. 5.
If the collar 42 is positioned coaxially with the bearings 38 in the device of FIG. 5, a standardly constructed doctor may be used, and such doctor may be lifted off, and oscillated, in a normal manner.
FIG. 6 shows an embodiment of the air-blowing member or doctor of the invention which functions to boost the effect of over-pressure in a pocket P of a multiple cylinder dryer. The device of FIG. 6 accomplishes this by turning inward the air blowing directions 43 closest to the edge by turning the corresponding apertures closest to the edge. This results in a corresponding fraction of the pulse effect of the air flow creating an inwardly directed force, which prevents over-pressure produced by air blown in other directions from discharging through the ends of the pocket P. This expedient may be implemented by turning the air-blowing members of FIGS. 3A and 4 inward at a suitable angle.
The invention is by no means restricted to the aforementioned details which are described only as examples; they may vary within the framework of the invention, as defined in the following claims.
It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the above constructions without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
|
An air-directing device for directing air to the multiple cylinder dryer of a paper machine includes members for blowing dry air into the vicinity of the web at those points where the evaporation of water from the web is strongest. This reduces the humidity in such regions and promotes the evaporation of water from the web. The points are the initial parts of the cylinder intervals after contact with the web. The air-directing device is so placed, and its air-blowing members are so disposed and directed, that the air blown out from such members is directed into the clefts defined by the surface of the drying cylinder and the paper web. This achieves a pressure effect in the clefts. The air-blowing members are primarily used in connection with single fabric conduction in pockets on the side of the web to urge the web fast to the fabric and are preferably disposed on a doctor beam or in conjunction therewith.
| 3
|
RELATED APPLICATIONS
[0001] This application is a Continuation of PCT application serial number PCT/RU2010/000581 filed on Oct. 13, 2010, published as WO 2011/049485 A1 on Apr. 28, 2011, which claims priority of Russian application serial number 2009140206 filed on Oct. 23, 2009, and both of which are incorporated herein by reference in their entirety.
TECHNICAL FIELD
[0002] Claimed invention relates to the hygiene and preventive healthcare. More specifically it relates to the methods and means for respiratory organs and eyes protection from aerosols.
PRIOR ART
[0003] There are known many methods and devices for protection of respiratory organs and eyes from aerosols. For example, in the Russian Federation patent No. 2030191 and U.S. Pat. No. 4,055,173 there are described various types of gas mask comprising a mask, tightly put on the face, air pipes and air pump supplying pure air under the mask for a breathing. However, the presence of airtight mask creates hygienic problems and discomfort for the user, namely, skin irritation and increased sweating where the user's face is in contact with the mask. Also there are restrictions for the user on the visual observation of the environment and on the voice communications. It becomes particularly clear during a long (several hours) wearing of such a device. Also the users, as a rule, tend to shun the wearing of similar devices with a mask for the aesthetic reasons.
[0004] There are also known other variants to protect respiratory organs and eyes from aerosols, which provide protective helmets (Russian Federation patent No. 2022579, U.S. Pat. Nos. 3,736,927 and 6,250,299), comprising a transparent visor covering the face, air filter, air fan with a portable power source and air pipes for aerosols purified air supply under the visor to the face. However, usage of said means leads to a limited user's visual observation and voice communications, as well as to the user's discomfort due to the considerable size and weight of said device. The helmet's wearing also violates the aesthetics appearance of the user, obscuring a significant part of the hairstyles and the face, which is violating mimic communications with other people. The visor's presence may also lead to the moisture condensation on its surface, which, in turn, leads to a loss of its transparency. In addition, the device does not preclude aerosol inhalation, because the design of the air pipes does not create directional air flow in the area of the nostrils and the mouth. Also the air flow velocity is low in this area due to the presence of the facial glass visor, so it allows aerosols to penetrate into the respiratory zone during inspiration.
[0005] Also there are known means for respiratory organs and eyes protection from aerosols (Russian Federation patent No. 2070823 and European patent application EP 0368916), comprising a fastening device on the user's head, a pump having a portable power unit and the filters, providing the source of the purified air, and the air pipes used to form the air curtain of aerosols purified air flow in the area of the respiratory organs (the nostrils and the mouth). However, there is a need for a preliminary purification of the air, which is forming said protective air curtain. It requires additional energy consumption and increases the cost, size and weight of the device. The increased weight and dimensions of the device also reduce user's comfort and convenience. In addition, passive air cleaning means (filters) do not ensure the complete removal of bacterial and viral aerosols during long term work. Also, all known active means of air sterilization (plasma discharge, UV irradiation, ozonation, etc.) contain high voltage components which could reduce electric safety of said devices. Moreover, all active means of biological sterilization during their operation provide harmful molecules and chemical radicals, which may be toxic for the user organism when inhaled.
[0006] The most close technical solution to the claimed invention is the Russian Federation patent No. 2255778, selected as the invention's prototype. Said prototype teaches the method and the device for respiratory organs and eyes protection against aerosols using a stream of preliminary purified (sterile) air for a breathing. Direction of the air stream axis coincides with the tangent line to the geometrical surface formed by the tip of the nose, chin and the jaws. Said air stream is provided using a pump with a portable power source, air filters and air flow pipes. However, according to the prototype, it is necessary to purify the air, which is forming said protective air stream. It requires additional energy consumption from the portable power source and increases the cost, size and weight of the device. The increased weight and size of the devices also reduce user's comfort and the usability convenience. In addition, passive air cleaning means (filters) do not ensure the complete removal of bacterial and viral aerosols during long term operation. Also all known active means for air sterilization (plasma discharge, UV irradiation, ozonation, etc.) contain high voltage components, which reduces the electrical safety of the device. Moreover, all active means of biological sterilization during their operation provide chemically active molecules (ozone, radicals, ions) which may be toxic for the user's organism when inhaled.
INVENTION DISCLOSURE
[0007] The goal of proposed invention is to create such a method and device for the respiratory organs and eyes protection against aerosols that would avoid immediate contact of protection means with the facial skin to achieve a high hygienic and aesthetic effect during a long-term wearing. Also the protection means must not block the sound channel for the conversation, and must have small overall dimensions, weight and power consumption for a high level of usability convenience and comfort.
[0008] This problem may be solved by creating a method for respiratory organs and eyes protection against aerosol particles of ambient air. According to the proposed method, the air flows are provided in the form of air curtain in front of the protected facial sites, namely, for individual or overall protection of nostrils, mouth and eyes, where, according to the proposed invention, said air flows are formed from the surrounding air without preliminary purification. Further said air streams (i.e. air flows) are directed in such a way that the stream lines do not cross the planes of the protected facial areas (inlet cross sections of the nostrils, mouth and eyes). At the same time, said air streams must carry aerosol particles beyond of said facial openings. The configuration of said air streams is chosen in such a way that any vector, carried out from any point of the space around the face to any protected facial opening, must be intersected by, at least, one of said air streams. Also the air stream velocity and its cross section must be chosen in such a way that aerosol particles, trapped by the stream from the surrounding space, would be accelerated enough to be ejected beyond of the protected facial areas.
[0009] Thus, if the aerosol particle tries to penetrate a breathing hole (nostrils, mouth), it will be obliged to cross the air stream which is generated in the form of the air curtain in front of said breathing hole. At the certain ratio between the mass of the particle, its cross-section size and the air stream velocity, the particle is captured (deflected and accelerated) by the air stream and is further moving at the speed of said air flow away from the protected breathing hole.
[0010] It is expedient that said air streams would be directed along the line of the lips towards from the cheeks to the nose.
[0011] Also it is expedient to direct these air streams perpendicular to the line of the mouth, from top to bottom.
[0012] Another variant of the invention is to form said air streams by air injection through the air pipes using a compressor powered by a portable source.
[0013] Also it is possible to create said air flows by a pumping of the air out of the area in front of said facial sites through the air pipes using a pump powered by a portable source.
[0014] Another variant of the invention is to attach said air pipes to the spectacle frame.
[0015] Also possible variant of the invention is to attach the air pipes to the phone headset frame.
[0016] Another expedient variant of the invention is to mount the air pipes on the dress.
[0017] One of expedient variants of the invention is to mount the air pipes on a headdress.
[0018] The technical result achieved by the proposed invention is in substantial reduction of energy consumption, size and weight of the device for implementation of the method proposed, as well as in a higher electrical safety level and in resolving of the problem with a toxic influence of air purification system on the user's organism.
[0019] The goal of the invention may be also achieved by the device for protection of respiratory organs and eyes against aerosol particles from the surrounding air. The device comprises fastening means to orient said device relative to person's face; at least one pump with a portable power supply source; air pipes connected to the pump and designed to form air streams in the form of protective air curtain before the protected sites of the face, including simultaneously or separately person's nostrils, mouth and eyes. According to the claimed invention, the pump is designed with a possibility to form the specified air streams directly from the surrounding air; outlets of the air pipes are directed relative to the face in such a manner that air flow lines don't cross the plane of entrance openings of protected facial sites. Said air streams must have such configuration that any vector, carried out from any point of the surrounding space through the air to the inlet opening of the protected facial site, is crossed, at least, by one of said air streams. Available pump rate must be taken into account: said air stream cross-section configuration and velocity must be chosen so that the acceleration, acquired by aerosol particle getting to said air stream from surrounding air, would be enough for its deflection from the protected facial opening.
[0020] One of the possible variants of the present invention comprises a vacuum pump for said air flows formation.
[0021] Another possible variants of the present invention comprises a compressor for pressurising ambient air to form said air streams.
[0022] Also possible is to use an axial fan as said compressor.
[0023] Another variant is to use a centrifugal fan as said compressor.
[0024] It is expedient that said air pipes are mounted in such a way that the air streams are directed along the line of the lips towards from the cheeks to the nose.
[0025] It is also expedient that said air pipes are mounted in such a way that the air streams are directed perpendicular to the mouth line from top to bottom.
[0026] It is expedient that said air pipes are mounted on a spectacle frame.
[0027] It is expedient that said air pipes are mounted on a phone headset frame.
[0028] It is possible to mount said air pipes on a clothes collar or on a headdress.
[0029] It is expedient to mount one or more air flow speed sensors on said air pipes for automatic regulation of the air flow rate at the protective air curtain to guarantee interception of aerosol particles when the velocity of the incident air with aerosols is increased.
[0030] The technical result achieved by the proposed invention is a common one both for the method of respiratory organs and eyes protection from aerosols and for the device for its implementation. It is substantial reduction in energy consumption level, size and weight of the device, as well as improvement in electrical safety and prevention of toxic influence by air sterilization system on the user's organism.
[0031] In addition, the proposed device does not provide difficulties for breathing, leaves open the mouth and the nose of the user and is not in a contact with the skin.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] For a better understanding of the claimed invention some variants of the invention embodiment are described with the references to the following drawings:
[0033] FIG. 1 shows a diagram explaining the principles of the moving aerosol particles deflection by the air stream from centrifugal fan (for simplicity a portable power source consisting of accumulator battery is not shown on the diagram).
[0034] FIG. 2 schematically shows the front view of the protective device fixed on the user's ears and forming the air curtain parallel to the lips line for the protection of the nostrils and mouth against aerosols. The device is mounted on the headset frame, while the power supply is in the pocket of the dress and is not shown on the diagram.
[0035] FIG. 3 schematically shows the front view of the protective device fixed on the user's head. It is forming the air curtain perpendicular to the mouth line from top to bottom. Power source is in the pocket of the dress and is not shown on the diagram.
DETAILED DESCRIPTION OF THE INVENTION
[0036] The claimed method of respiratory organs and eyes protection from the ambient aerosol particles provides air streams in the form of the air curtain in front of the protected facial sites, including individual or overall protection of the nostrils, mouth and eyes. These air streams are formed from the surrounding air without preliminary purification, said air streams are directed in such a way that the air flow lines do not cross the plane of the protected facial openings and are caning away aerosol particles from protected facial openings. Configuration of these air streams are chosen in such a way that any vector, carried out from any point of the face surrounding space through the air to protected openings, is crossed by, at least, one of said streams. The speed and the cross-section of the air stream are chosen in such a way that acceleration provided by said air stream to aerosol particles is sufficient for a deflection of aerosols incident from the surrounding air and for ejection of these aerosols away from the protected areas.
[0037] Said air streams can be directed, for example, along the lips line from the cheeks to the nose, or perpendicular to the mouth line, from top to bottom. These air streams may be provided by pressurising of the air through the air pipes using compressor with a portable power source or by a sucking out of the air from said facial area through the air pipes using vacuum pump with a portable power source. These air pipes may be mounted, for example, on a spectacle frame, on a phone headset frame, on a clothing or on a headdress.
[0038] It is common known that healthcare problems occur when human is exposed to harmful aerosol particles, which are inhaled through the nostrils and mouth. In particular, the flu virus and the tuberculosis bacilli are transferred by airborne droplets from person to person. Aerosol particles, dangerous when inhaled, have sizes from 0.1 μm or more (in a smaller aerosol particle bacterium or virus can not be accommodated) and are suspended in the air, where they make enough long chaotic Brownian motion before falling to the ground. Aerosol particles with size of 100 microns or more quickly fall out of the air. Aerosol particles with size more than 10 μm can not penetrate into the most vulnerable sections of the lower lungs, as when they move on the heavily curved trajectories through the respiratory tract (nose, throat and trachea), they will likely settle on the upper respiratory tract walls, where their pathogenic effect is lower. It is well known that the average speed of the Brownian motion of aerosol particles in a still air under normal conditions is 0.1 m/s or less. It means that these aerosol particles almost stand still in the air, and people, coming in the area of their location, simply suck them during inspiration.
[0039] Obvious, that the most dangerous from the point of view of a possible disease transfer for a person it is staying in a room, where ill people may extend viruses and bacteria by airborne way through the sneezing, cough and conversation. Very often there is no significant air motion here (but a good ventilation could reduce concentration of the harmful aerosols). In the modern life conditions people spend most time in the closed rooms or in the public transport vehicles where the process of cross contamination during epidemics occurs. Thus, people inhale suspended particles almost motionless in the coordinates' framework connected with the room, where the particles speed relative to respiratory openings (the nostrils and the mouth) doesn't exceed 1.5 m/s (speed of a walking person). Therefore, if, according to claimed invention, to create air stream (air curtain) parallel to inlet plane of respiratory opening with sufficient flow speed (for example, 10 m/s and more), the aerosol particle, which has got to the air stream, will be caught (deflected and accelerated) by this air stream. After trapping the aerosol particle will continue motion with the speed of said air stream; this circumstance will prevent its hit into respiratory organs. Note also, that air flow speed at the nostril inlet during a breath doesn't exceed averaged 2 m/s, and it sharply falls when leaving the vicinity of the nostrils because of the rapid increase in cross-section of inhaled flow. Therefore, a breath (as the most dangerous breathing phase for aerosol penetration) doesn't change considerably the air flow vectors in said air curtain at its speed of 10 m/s and more. During breath through an open mouth the total cross-section of the inlet opening is even more compared with the nostrils, therefore the speed of inhaled air is additionally decreased, and the changes of air stream vectors at a breath through the mouth are even less. Let's also note that formation of the air curtain around the nostrils and the mouth doesn't break conditions for a normal breathing. It takes place because of air molecules have a mass, much smaller that of the aerosol particles, thus the main molecules of the air (oxygen, nitrogen and carbon dioxide), participating in breathing, move with the speed of near to 500 m/s in the free diffusion mode. It quickly equalizes any gradients of the air molecules concentration, ensuring free breathing (gas exchange) of the protected person. Thus, the specified air curtain will protect respiratory organs against penetration of incident aerosol particles through the curtain and, at the same time, provide a free breathing.
[0040] At the same time, if the aerosol particle was in the air stream at the moment of its formation (when said air stream is generated in the pump and pipes from the surrounding air with possible aerosols presence and without preliminary purification), the particle is accelerated (caught) along with the flow of the air curtain and acquires curtain's flow speed and motion vector, which is parallel to the inlet plane of the breathing hole. In this way this particle will not be able to get into said breathing hole. Such a system of nostrils, mouth and eyes protection represents a respirator with inertial gasdynamic isolation, and therefore it does not require preliminary air purification means for the air curtain formation.
[0041] In order to determine conditions for formation of protective air curtain, let's consider a spherical droplet 1 on FIG. 1 , moving with the speed v 0 across the air stream 2 . Let air stream 2 has flow speed v s , width L and is formed using the pump 3 (for example, compressor) and the air pipe 4 . Air flow vectors of the air stream are shown on FIG. 1 by arrows N emanating from the air pipe 4 . The inlet opening of breathing organ (the nostril or the mouth) is designated with 5 . We assume, that at the moment, when the droplet 1 entered the air stream 2 , the transverse component of its velocity v=0. The force of air resistance F is applied to the droplet 1 , when it enters the air stream 2
[0000] F= ½ ·C·S ·( v−v s ) 2 (1)
[0000] where:
ρ—air density;
S—the squared cross-section of the droplet;
C—dimensionless factor, which for a spherical body equals 0.47.
[0042] Mass of the droplet 1 equals 4/3·π·ρ 0 ·R 3 , where ρ 0 is water density, R—radius of the droplet. The squared cross-section of the spherical droplet equals to π·R 2 .
[0043] Acceleration experienced by the droplet 1 inside of the air stream as a function of time t is equal to:
[0000] dv ( t )/ dt= ⅜·(ρ/ρ 0 )·( C/R )·( v−v s ) 2 (2)
[0044] Solving Equation (2) with initial conditions v(0)=0, one can find that the transverse velocity of the droplet 1 varies in time during passage of the air stream in accordance with the following expression:
[0000] v ( t )= v s ·t/ ( t+ 8/3 ·ρ·R/ ( C·ρ 0 ·v s )) (3)
[0045] It may be derived from (3) that the time t 0.5 , when the droplet 1 will achieve a half of the velocity v s in the transverse direction, is equal
[0000] t 0.5 = 8/3 ·ρ·R/ ( C·ρ 0 ·v s ) (4)
[0000] Taking into account that ρ/ρ 0 ˜1000, one can get
[0000] t 0.5 (sec)=0.005 ·R/v s (5)
[0000] where R is expressed in microns and v s —in m/s. The distance x(t), which the droplet 1 passes in the transverse direction (along the air stream vector), is determined by time integrating of the expression (3):
[0000] x ( t )= v s ·( t−t 0.5 ·ln(( t+t 0.5 )/ t 0.5 )) (6)
[0046] Consider an example of practical implementation: let the droplet 1 of 10 μm size tries to penetrate the air curtain (air stream 2 ) having 2 cm thickness and 10 m/s flow speed. According to (5), in this case t 0.5 =0.005 s. If the droplet 1 moves through the air curtain with a speed v 0 =2 m/s (corresponding to a very rapid movement of the user with near to 7 km/h velocity), time of the possible crossing of the air stream 2 by the droplet 1 is equal to L/v 0 =0.01 s. During this time duration (equal to the doubled t 0.5 ) in accordance to equation (3) the droplet 1 acquires speed 6.6 m/s along the air stream 2 direction and, according to equation (6), it passes distance x(t)=5 cm. The resultant velocity V res of the droplet 1 will be about 7 m/s, and the direction of its vector is shown on FIG. 1 . Thus, the droplet 1 will pass beyond the entrance hole 5 of the breathing organ and is unable to get into it. Therefore, it will be ejected by the air curtain. Let's consider another droplet 1 a , which would fell into the breathing hole 5 in the case of air stream 2 being off. The trajectory of the droplet 1 a in this case is shown by the dotted line M 1 on the FIG. 1 . In the case of the air stream 2 presence the droplet 1 passes beyond the breathing hole 5 at the trajectory shown by solid line M 2 on the FIG. 1 .
[0047] The proposed on the FIG. 2 device for the user's 6 respiratory organs and eyes protection from aerosols is intended for considerable decrease of harmful aerosol penetration into user's organism during the breathing. It comprises a portable power supply source (not shown on the drawing), the pumps 3 , 3 a and the air pipes 4 , 4 a forming air streams 2 (air curtain) before inlet openings of respiratory organs (nostrils and mouth). On the role of the pump 3 , it can be used some vacuum device for air suction, or various compressors for air pumping. It is also possible to use miniature industrial fans with rotating blades, in particular, axial fans (air is accelerated in the direction parallel to the rotation axis of the blades) or centrifugal ones (air is accelerated in the direction perpendicular to the rotation axis of the blades). Such fans may be powered by DC voltage 5-12 V and current ˜0.1 A, thus the battery of accumulators with electric capacity 3-5 A·hour can provide continuous operation of the protecting device during a full day time.
[0048] According to the proposed invention, the air pipe 4 may be of various configurations, in particular, it can be used a combination of one or more pipes to protect each of the entrance openings of the breathing organs and eyes (see FIG. 2 , where pipes for eyes protection are not shown for simplicity of the drawing) or it may be a pipe for overall facial area protection (see FIG. 3 ).
[0049] It is known that, if the speed of the air stream will not exceed a few dozen m/s, the air pipes 4 with a smooth internal surface will generated a laminar air flow 2 . Thus the cross section of the air stream 2 will be similar to the outlet configuration of the air pipe 4 . Leaving the pipe 4 , the air stream will gradually expand and slow down. Thus, to create the air curtain of the predetermined shape (width and thickness), it is necessary to provide the same shape to the outlet of the air pipe 4 . For example, to protect the nostrils and the mouth, as shown on FIG. 2 , it can be used air pipes 4 and 4 a having rectangular outlet with rounded corners (to reduce possible turbulence around the corners). For the variant shown on FIG. 3 , taking into account the anatomic feature of the user's face (nose), one can use the air pipe 7 , having on the cross-sectional view a shape of circle arc with a constant width (as a protective plastic shield on the helmet of ice hockey player).
[0050] Flow lines of the air curtain are shown on FIG. 2 by arrows N emanating from the air pipes 4 and 4 a , on FIG. 3 —by arrows N emanating from air pipe 7 . The length of air pipes 4 , 4 a and 7 may be various, but it should be sufficient to form homogenious air stream 2 , despite of some air disturbances arising at the exit from the air pumps 3 and 3 a . The length of the pipes 4 , 4 a , 7 is also determined by considerations of a user-comfortable location of the pumps 3 , 3 a forming protective air curtain. If possible, this length should be kept minimal to reduce aerodynamic resistance in the pipe segment between the pumps 3 , 3 a and the outlets of air pipes 4 , 4 a , 7 . In this way it may reduce power consumption by the pumps 3 and 3 a . Air pipes 4 , 4 a , 7 should have a smooth inner profile and a gradual change of cross-section from the entrance, connected to the pump, and up to the pipe outlet to form a laminar air flow. In this case the air stream 2 will keep its speed and direction of motion for a maximum time after exiting from the outlet of the air pipes 4 , 4 a , 7 . Also, the pipes 4 , 4 a , 7 may have a various curved shape in such a way that, depending on the individual face shape of the user 6 , the speed vector of the air stream 2 , protecting the facial openings of the breathing organs, may be directed parallel to the inlet plane of said breathing holes. Also the air stream 2 configuration in the area of the breathing hole must create the air curtain, i.e. any vector, which is drawn from any space point in front of the user's face and which is crossing the inlet plane of the breathing hole, should intersect one of said air streams. In this case, if the aerosol particle (droplets 1 and 1 a on FIG. 1 ) is trying to get, for example, into the nostril, said particle hits the air stream 2 of the curtain. In this case said air stream 2 flows transversively to the particle and, at a certain ratio between the mass of the particle, its cross-sectional size and the air stream velocity, the particle is captured (deflected and accelerated) by the air stream and further continues to move at the speed of this stream away from the protected opening.
[0051] The cases of the pumps 3 , 3 a , as well as of the air pipes 4 , 4 a , 7 may be made from a plastic to reduce weight. Additionally, one can use plastic transparent to the visible light and ultraviolet radiation, it will provide access of sunlight to the skin of the face.
[0052] Because it is necessary to provide a spatial fixation of said protective device relative to the nostrils and the mouth of the user 6 , you can use a variety of options for fastening device. For example, it is possible to mount said protective device on the spectacle frame (not shown on the drawings) or with the headset frame 8 , tightly fixed on the head. Also for user 6 convenience, it is possible to mount said protective device on a headdress (not shown on the drawings), a head ribbon 9 or with a dress elements (not shown on the drawings).
[0053] Additionally, in said protective device it can be installed one or more air flow speed sensors (not shown on the drawing) for automatic regulation of the air curtain flow rate and for the enhanced interception of aerosol particles in the case of the increase in the oncoming speed of the ambient air. It also permit to save battery power, when the surrounding air is practically motionless and the flow rate may be decreased. In this case, for example, one can use well known design of the open case thermo-resistors installed inside of airflow to be measured. Said thermo-resistors with the stabilized heating means as an airflow speed sensors, microprocessor for data analysis from said thermo-resistors and DC-DC converter for a voltage supply regulation of the pump motor power are possible to use for this purpose.
[0054] FIG. 2 demonstrates a variant of the protective device which is mounted on the user's head 6 and which is producing air curtain (air streams 2 ) along the line of the lips 10 in the direction from the cheeks 11 toward the nose 12 . The pumps 3 and 3 a (in this case the centrifugal fans are used) should have size, capacity, volumetric efficiency and output pressure sufficient to create air streams 2 with necessary flow speed and cross section value, as is explained on the FIG. 1 and by the analysis of equations (1-6).
[0055] The pumps 3 and 3 a are tightly connected with air pipes 4 and 4 a with rectangular outlet cross-section to form a protective air curtain with required width and thickness. Pumps 3 and 3 a are mounted by the frames 8 , 8 a to the headset, which provides secure fixation of the device at the user's 6 head. Air pipes 4 and 4 a are attached in such a way that their axes are intersected at some angle to each other (for example, 90°) to avoid opposing interference with each other. In this case at the streams' intersection region the resultant airflow will be directed opposite to the person's face and will throw away the captured aerosol particles. Anatomical features of user's 6 face (which is convex in a horizontal section plane) contribute to the easy implementation of the necessary intersection angle. Also the pumps 3 and 3 a are cable connected to a power source with a turn on/off switch (are not shown on FIG. 2 ) which may be held in the pocket of the dress or in any other convenient place for the user 6 .
[0056] Said device is sucking surrounding air (as shown on the FIG. 1 and FIG. 2 by the arrows K) into round inlet holes of the pumps 3 and 3 a , and there is no preliminary air purification. Using air pipes 4 and 4 a , the protective air streams 2 are formed in the directions, shown by arrows N on the FIG. 2 , on this way the air streams 2 deflect aerosol particles flying in the direction of entrance openings of the nostrils and mouth. Thus the air pipes 4 and 4 a are directed relative the face of user 6 so, that air streams 2 pass beyond (do not cross and do not touch) the plane of the nostrils and the mouth inlet holes. It prevents inhalation of aerosol particles carried by the air streams 2 , aerosols are present here due to streams formation in the pumps 3 , 3 a without preliminary purification.
[0057] On the FIG. 3 it is shown another version of the proposed protective device, which is fixed on the head of the user 6 and is forming the air curtain perpendicular to the mouth line 10 from top to down. Pumps 3 and 3 a with necessary parameters (in this case it is also possible to use centrifugal DC fans) are tightly connected to the air pipe 7 having in cross-sectional view a form of a circle arch with a width, sufficient for simultaneous protection of eyes, nostrils and the mouth (similar to protective plastic helmet guard of ice hockey player). The thickness and the speed of the air curtain formed should be sufficient for performance of protective functions, as was analyzed in equations (1-6). The cross-section of the air pipe 7 closer to the outlet may have the rounded corners for reduction of turbulence of the formed air stream 2 . The pumps 3 , 3 a and the air pipe 7 are attached to a head tape 9 which provides reliable fixation of the device on the user's 6 head or on the headdress (is not shown on the drawing). Pumps 3 and 3 a are connected through a cable to a power supply source with the on/off switch (not shown on the drawing) which can be held in a pocket of clothes or in any other place, convenient for the user 6 .
INDUSTRIAL APPLICABILITY
[0058] The proposed method and the device are designed to prevent harmful aerosols (bacteria, viruses, allergens in various forms, including liquid drops, as well as various kinds of dust) penetration into the human respiratory system, including the upper respiratory ways, as well as in the eyes and on the skin of the face.
|
The invention relates to a method that comprises generating air flows ( 2 ) in the form of an air curtain in front of openings of the face to be protected using ambient air without preliminary purification, and directing said flows ( 2 ) in such a way that the flow lines do not intersect the planes of the openings of the face to be protected and reject aerosol particles in the vicinity of said openings. The configuration of the flows ( 2 ) is selected so that any vector extending from the surrounding medium through the air into the plane of the openings of the face to be protected, intersects at least one of said flows ( 2 ). The speed and the transverse section of the flow ( 2 ) are selected so that the acceleration gained by the aerosol particles falling into the flow from the surrounding medium, is sufficient for diverting them from the sections of the face to be protected. The device of the present invention comprises a portable power unit and pumps ( 3, 3 a ) generating air flows in the form of an air curtain in front of the inlet openings of the breathing organs ( 5 ) (nostrils ( 12 ) and mouth), wherein the speed vector of the flows ( 2 ) is parallel to the planes of said openings. The flows ( 2 ) have a speed (more or equal to 10 m/s) sufficient for trapping the aerosol particles that may penetrate the breathing openings and for rejecting them aside together with the flow ( 2 ) away from the breathing organs ( 5 ). The air flows ( 2 ) are generated by the pump ( 3, 3 a ) directly from ambient air with the aerosol particles contained therein, but due to the speed thus obtained, the flows ( 2 ) maintain within themselves said aerosol particles that pass beyond of the breathing openings due to inertia.
| 0
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an ink, a recording method employing the ink, and an apparatus charged with the ink. In particular, the present invention relates to an ink which exhibits less blurring of images recorded on a recording medium which has an ink-receiving surface layer composed of a binder and a pigment, a recording method employing the ink, and an apparatus charged with the ink.
1. Related Background Art
Conventionally, for ink-jet recording, an aqueous ink is used which comprises a water-soluble dye and an aqueous medium for solving the dye. The ink for ink-jet recording needs to meet the requirements below:
(1) The ink gives an image of sufficient density.
(2) The ink dries quickly on a recording medium.
(3) Feathering on a recorded image appears little.
(4) The recorded image does not flow out when the image is brought into contact with water or alcohol, or is decipherable enough even if some flow-out of the ink occurs (water-fastness).
(5) The ink or the recorded image has sufficient light-fastness.
(6) The ink does not clog at a penpoint or an ink nozzle.
(7) The ink is stably ejected during continuous recording or after interruption of recording for a long time without causing defects such as blurring of a recorded image (ejection stability).
(8) The ink is stable in storage.
(9) The ink does not damage members brought into contact with the ink.
(10) The ink is safe for persons handling the ink, the safety including negativeness in Ames test.
In ink-jet recording utilizing thermal energy, the ink needs further to meet an additional requirement below:
(11) The ink has a sufficient thermal stability, and does not adversely affect a thermal energy-generating means.
Black inks which meet the above requirements on plain paper are disclosed in Japanese Patent Application Laid-Open Nos. 1-135880 and 1-193375. A color ink for full-color image formation is disclosed in Japanese Patent Application Laid-Open No. 62-199667. The inks of prior art, however, do not necessarily satisfy all the requirements enumerated above.
In particular, in full-color image formation, a problem remains unsolved that a formed image blurs after leaving it for a long term. For full-color image recording, in order to obtain sharp images, recording mediums (coated paper) are usually used which have ink-receiving surface layer comprising a pigment and a binder. The coated paper causes significantly the above-mentioned blurring.
Of four colors including black, cyan, magenta, and yellow, the magenta color is especially liable to cause blurring, and in an extreme case, the printed letters have peripheral margins of magenta color, which impairs remarkably the image quality after leaving it for a long time.
Examples of magenta dyes are disclosed in Japanese Patent Application Laid-Open Nos. 58-176277, 59-78273, 60-81266, 62-190271, 62-199665 to 62-199667, and 1-53976. Each of these dyes has both advantages and disadvantages: some dyes are excellent in light-fastness, but give unclear color; some dyes are satisfactory in water-fastness and non-bleeding, but are poor in light-fastness; and some dyes are satisfactory in light-fastness and water-fastness, but discolor even under room conditions.
Japanese Patent Application Laid-Open No. 62-187773 discloses the use of a dye of the formula ##STR2## However, this dye has disadvantages in light-fastness and storage stability.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a magenta ink which satisfies the aforementioned general requirements, causes less blurring of images after leaving them for a long term, and gives images which discolor less under room conditions.
Another object of the present invention is to provide a recording method which employs the above ink.
A further object of the present invention is to provide an apparatus which employs the above ink.
The ink of the present invention comprises at least a dye and a liquid medium, the dye being represented by the general formula ##STR3## wherein Y is a linear or branched alkyl group having 5 to 12 carbons; Z is a benzoyl group, a radical of the formula --SO 2 C 6 H 5 or --SO 2 C 6 H 4 --CH 3 ; and M is an alkali metal or ammonium.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic sectional view of a recording head of an ink-jet recording method of the present invention.
FIG. 2 is a schematic sectional view of the recording head at the line A-B in FIG. 1. 5 12
FIG. 3 illustrates schematically an external appearance of a multiple head having a plurality of heads of FIG. 1 in juxtaposition.
FIG. 4 is a schematic perspective view of an ink-jet recording apparatus having the above head mounted thereon.
FIG. 5 is a schematic sectional view of an ink cartridge for supplying an ink to the above head.
FIG. 6 illustrates schematically an appearance of an essential part of the ink-jet recording apparatus in which the head and the ink cartridge are integrated.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The ink comprising the dye represented by the general formula (I) enables formation, on a coated paper sheet, of an image which does not blur after leaving it for a long time and which is of high quality and high resolution, exhibiting less discoloration, and having high fastnesses.
The ink of the present invention is useful for ink-jet recording in which ink is ejected by action of thermal energy. In the ink-jet recording, the ink does not form a sticking matter on the heater and can be used stably for a long time. Further, the ink neither deteriorates in its properties nor forms solid deposit.
By use of a dye of the specified structure as the coloring matter, the ink satisfies the above-mentioned general requirements, and gives an image which does not blur even when the images is formed on a coated paper sheet and left for a long term, and which has excellent light-fastness and is less liable to discolor in a room conditions.
The present invention is described below in more detail by reference to preferred embodiments.
Any of the dyes employed in the present invention has generally a sodium salt form of a water-solubilizing group such as a sulfo group. However, the dye of the present invention is not limited to a sodium salt form, but a salt form with potassium, lithium, ammonia, or organic amines such as an alcoholamine are also effective similarly, and such salts are included in the present invention.
The dye represented by the above general formula (I) is exemplified specifically by the dyes of the structural formula below. In the general formula (I), the substituent Y is preferably a branched or non-branched alkyl group of 5 to 12 carbons for the purpose of obtaining desirable magenta color and of preventing blurring. If the substituent is linked with interposition of an amino group, the color tone deviates greatly from magenta. ##STR4##
The amount of the dye to be used in the ink of the present invention is generally in the range of from 0.1 to 15% by weight, preferably from 0.3 to 10% by weight, more preferably from 0.5 to 6% by weight of the total weight of the ink, but is not limited thereto.
The suitable aqueous medium for the ink of the present invention is water or a mixed solvent composed of water and a water-soluble organic solvent. The water is not common water containing various ions, but preferably deionized water.
The water-soluble organic solvent to be mixed with water includes conventional water-soluble organic solvents used in ink-jet recording. In particular, glycerin and polyethylene oxide of polymerization degree of 3 to 6 are effective in prevention of clogging of nozzles by inks. Nitrogen-containing cyclic compounds and polyalkylene oxide ethers are effective in improvement of image density and ink ejection stability. Lower alcohols and surfactants are effective in improvement of frequency response. Accordingly, preferred solvent compositions in the present invention contain the above various solvent components in addition to water.
The above water-soluble organic solvent is contained in the ink in an amount of generally from 2 to 80% by weight, preferably from 3 to 70% by weight, more preferably from 4 to 60% by weight.
The water is used in an amount of not less than 10% by weight, preferably from 10 to 97.5% by weight. Use of less amount of the water is undesirable since it increases the amount of a less volatile organic solvent remaining in the formed image to cause migration of the dye or blurring of the formed image.
The ink of the present invention may contain a pH-adjusting agent, a viscosity-adjusting agent, a surface tension-adjusting agent, or the like in addition to the above components, if necessary. The pH-adjusting agent includes organic amines such as diethanolamine and triethanolamine; inorganic alkaline salts such as alkali metal hydroxides, e.g., sodium hydroxide, lithium hydroxide, potassium hydroxide, etc.; organic acid salts such as lithium acetate; organic acids, inorganic acids, and so forth.
The ink of the present invention as described above has a viscosity at 25° C. of from 1 to 20 cP, preferably from 1 to 15 cP, a surface tension of not less than 30 dyn/cm, preferably not less than 40 dyn/cm, and pH of from about 3 to about 10.5.
The ink of the present invention is effectively used in ink-jet recording and in the use of coated paper as a recording medium which allows formation of an image with high sharpness and high resolution.
The ink-jet recording may be conducted by any conventionally known method. For example, the method and the apparatus disclosed in Japanese Patent Application Laid-Open No. 54-59936 are useful where the ink is ejected through a nozzle by a force given by abrupt volume change of the ink on receiving thermal energy.
One example of the ink-jet recording apparatus of the present invention is explained below. FIGS. 1, 2, and 3 illustrate construction of a head which is the essential part of the apparatus.
In the drawings, the head 13 is constructed by bonding a plate of glass, ceramics, or plastics having grooves 14 for ink flow with a heating head 15 for thermal recording. (The head is not limited to the one as shown in the drawings.) The heating head 15 is constituted of a protection layer 16 formed of silicon oxide or the like, aluminum electrodes 17-1, 17-2, a heating resistor layer 18 made of nichrome or the like, a heat-accumulating layer 19, and a heat-radiating substrate plate 20 made of alumina or the like.
The ink 21 reaches an ejection orifice (fine nozzle) 22, and a meniscus 23 is formed there by a pressure P.
On application of an electric signal information to the electrodes 17-1, 17-2 of the head, the region denoted by a symbol "n" on the heating head 15 generates heat abruptly to form bubbles in the ink 21 on the region, the pressure of the bubble pushes out the meniscus 23, and ejects ink from the orifice 22 in a shape of droplets 24. The ejected ink droplets travel toward a recording medium 25.
FIG. 3 shows an appearance of a multiple head having a plurality of the above head in juxtaposition. The multiple head is formed by bonding a glass plate 27 having multiple grooves 26 with the heating head 28 like the one shown in FIG. 1.
FIG. 1 is a sectional view of the head 13 along the ink flow path. FIG. 2 is a sectional view of the head at the line A-B in FIG. 1.
The ink in the present invention can be maintained at an operating temperature (a controlled recording temperature) by heating the substrate plate 20 to keep whole the head at a constant temperature, or by the like method.
The ink of the present invention kept at an operating temperature as above has a viscosity lower than that at non-operating conditions owing to the action of a compound having a thermally reversible gelation characteristics, thereby the head exhibiting a satisfactory ejection characteristics.
FIG. 4 illustrates an example of the ink-jet recording apparatus having such a head mounted thereon. In FIG. 4, a blade 61 as a wiping member is held at one end of the blade by a blade-holding member, forming a fixed end in a shape of a cantilever. The blade 61 is placed at a position adjacent to the recording region of the recording head, and, in this example, is held so as to protrude into the moving path of the recording head.
The cap 62 is placed at a home position adjacent to the blade 61, and is constituted such that it moves in the direction perpendicular to the moving direction of the recording head to come into contact with the ejection nozzle face to cap the nozzle. An ink absorbent 63 is placed at a position adjacent to the blade 61, and is held so as to protrude into the moving path of the recording head in a manner similar to that of the blade 61.
The blade 61, the cap 62, and the absorbent 63 constitute an ejection recovery device 64. The blade 61, and the absorbent 63 serve to remove off water, dust, and the like from the face of the ink ejection nozzle.
A recording head 65 has an energy-generating means for the ejection, and conducts recording by ejecting the ink onto a recording medium opposing to the ejection nozzle face. A carriage 66 is provided for supporting and moving the recording head 65.
The carriage 66 is engaged slidably with a guide rod 67. A portion of the carriage 66 is connected (not shown in the drawing) to a belt 69 driven by a motor 68, so that the carriage 66 is movable along the guide rod 67 to the recording region of the recording head 65 and the adjacent region thereto.
A paper delivery device 51 for delivery of a recording medium and a paper delivery roller 52 driven by a motor (not shown in the drawing) delivers a recording medium to the position opposing to the ejection nozzle face of the recording head, and the recording medium is delivered with the progress of the recording to a paper discharge device provided with paper-discharging rollers 53.
In the above constitution, when the recording head 65 returns to the home position on completion of recording, the cap 62 of the ejection-recovery device 64 is positioned out of the moving path of the recording head 65, and the blade 61 is allowed to protrude to the moving path. Thereby, the ejecting nozzle face of the recording head 65 is wiped. To cap the ejection face of the recording head 65, the cap 62 protrudes toward the moving path of the recording head to come into contact with the ejection nozzle face.
When the recording head 65 is made to move from the home position to the record-starting position, the cap 62 and the blade 61 are at the same position as in the above-mentioned wiping step, so that the ejection nozzle face of the recording head is wiped also in this movement. The recording head is moved to the home position not only at the completion of the recording and at the time of ejection recovery, but is also moved at a predetermined intervals during recording from the recording region. The nozzle is wiped by such movement.
FIG. 5 is a sectional view of an example of the ink cartridge which holds an ink to be supplied through an ink supplying member such as a tube. The ink container 40, for example an ink bag, contains an ink to be supplied, and has a rubber plug 42 at the tip. Insertion of a needle (not shown in the drawing) into the plug 42 enables supply of the ink from the ink bag 40. A waste-ink absorbent 44 serves to absorb a waste ink. The liquid-contacting surface of the ink container is preferably made of polyolefin, particularly preferably made of polyethylene in the present invention.
The ink-jet recording apparatus used in the present invention is not limited to the above-mentioned one which has separately a head and an ink cartridge. Integration thereof as shown in FIG. 6 may suitably be employed. In FIG. 6, a recording unit 70 houses an ink holding member such as an ink absorbent, and the ink in the absorbent is ejected from a plurality of orifices of a head 71.
The ink absorbent is made preferably of polyurethane, cellulose, or polyvinyl acetal. An air-communication opening 72 is provided to communicate interior of the cartridge with the open air. The recording unit 70 may be used in place of the recording head shown in FIG. 3, and is made to be readily mountable to and demountable from the carriage 66.
The recording medium employed in the present invention may be made of any material including plain paper sheets, coated paper sheets, and plastic films for OHP and other uses. In particular, coated paper exhibits remarkable effects. Generally, the coated paper has an ink-receiving surface layer composed of a pigment and a binder on a plain paper or a wood-free paper as the base material. In the present invention, the coated paper includes the one having, in the ink receiving layer, paper fibers of the base material mixed therein.
The present invention is described below in more detail by reference to Examples and Comparative Examples. In the description below, "%" is based on weight, unless otherwise mentioned. The degree of blurring was estimated by comparison with inks prepared by mixing C.I. Direct Blue 199 (non-blurring dye), and a dye of the present invention.
The dyes used were synthesized according to a conventional method as below.
A solution of p-n-decylaniline-o-sulfonic acid was diazotized with sodium nitrite, and the diazotized product was coupled with benzoyl H-acid at pH 4 to 7. After the reaction, the product was salted out by addition of sodium sulfate, and collected by filtration. The collected matter was dissolved again in water, and deposited by addition of isopropyl alcohol for desalting to obtain Dye No.1. Dyes No.2 and No.3 were synthesized in a similar manner.
Inks of the Examples were prepared by mixing the components below.
EXAMPLE 1
______________________________________Dye No. 1 1.5%C.I. Direct Blue 199 1.5%Diethylene glycol 30%Deionized water 67%______________________________________
EXAMPLE 2
______________________________________Dye No. 2 1.5%C.I. Direct Blue 199 1.5%Diethylene glycol 20%Polyethylene glycol 10%(Average molecular weight 300)Deionized water 67%______________________________________
EXAMPLE 3
______________________________________Dye No. 3 1%C.I. Direct Blue 199 1%Diethylene glycol 15%N-methyl-2-pyrrolidone 15%Deionized water 68%______________________________________
EXAMPLES 4 TO 6
Inks of single magenta color were prepared in Examples 4 to 6 by replacing the C.I. Direct Blue 199 in the above Examples respectively with each of the Examples 1 to 3.
Components mentioned above were mixed sufficiently to prepare each solution, and the solution was filtered with a Teflon filter of pore diameter of 0.22 μm under pressure to obtain each of inks of the present invention.
The ink was applied to an ink-jet printer, Model BJ-130A (manufactured by Canon K.K., having 48 nozzles) which employs heat-generating element as the ejection energy source. Solid printing was conducted with this printer in the area of 15 mm×30 mm on the recording mediums A and B mentioned below. The printed matter was tested for blurring (Examples 1 to 6), weatherability (Examples 4 to 6), and discoloration (Examples 4 to 6).
Recording medium A: Coated paper for ink-jet printer manufactured by Sharp Corporation
Recording medium B: Coated paper for PIXEL PRO manufactured by Canon K.K.
"Accelerated blurring test"
The printed matter was left standing in the atmosphere of 30° C. and 80% RH for 48 hours. As the results, no blurring was observed satisfactorily in any of the Examples.
"Weatherability test method"
The printed matter was placed in a light exposure tester (Fade-O-meter, Model Ci35, manufactured by Atlas Electric Devices Co., Chicago, Ill.) for 100 hours. The color difference ΔE * ab caused by the test was obtained by measurement before and after the test. In any of Examples the value of ΔE * ab was not more than 15, and less discoloration was observed to obtain a satisfactory result.
"Accelerated discoloration test"
The printed matter was left standing for 120 minutes in a dark chamber in which ozone concentration was kept at 3±2 ppm The color difference ΔE * ab before and after the test was measured according to JIS Z-8730. In any of Examples the value of ΔE * ab was not more than 10, and less discoloration was observed to obtain a satisfactory result.
For comparison, the components below was mixed in the same manner as in Examples above to prepare inks. With these inks, solid printing was made on the recording mediums A and B by means of the same recording apparatus as above. The printed matters were tested for blurring, and discoloration. The printed matter of Comparative Example 1 exhibited significant blurring and discoloration. The printed matters of Comparative Examples 2 to 4 exhibited less blurring, but significant discoloration as magenta single color.
Comparative Example 1
______________________________________C.I. Acid Red 35 1.5%C.I. Direct Blue 199 1.5%Diethylene glycol 30%Deionized water 67%.______________________________________
Comparative Example 2
______________________________________C.I. Reactive Red 23 1.5%C.I. Direct Blue 199 1.5%Diethylene glycol 20%Polyethylene glycol 10%(Average molecular weight 300)Deionized water 67%.______________________________________
Comparative Example 3
______________________________________C.I. Reactive Red 23 3%Diethylene glycol 20%Polyethylene glycol 10%(Average molecular weight 300)Deionized water 67%.______________________________________
Comparative Example 4
______________________________________Dye of the formula 3% ##STR5##Thiodiglycol 5%Urea 5%Glycerol 5%Isopropyl alcohol 5%Deionized water 77%.______________________________________
The ink comprising the dye represented by the general formula (I) of the present invention enables formation, on a coated paper sheet, of an image which does not blur after leaving it for a long time, and which is of high quality and high resolution, exhibiting less discoloration, and having high fastnesses.
The ink of the present invention is useful for ink-jet recording in which ink is ejected by action of thermal energy. In the ink-jet recording, the ink does not form a sticking matter on the heater and can be used stably for a long time. Further, the ink neither deteriorates in its properties nor forms solid deposit.
By use of a dye of the specified structure as the coloring matter, the ink satisfies the above-mentioned general requirements, and give an image which does not blur even when the images is formed on a coated paper sheet and left for a long term, and which has excellent light-fastness and is less liable to discolor in a room conditions.
|
Provided is an ink comprising at least a dye and a liquid medium, the dye being represented by the general formula ##STR1## wherein Y is a linear or branched alkyl group having 5 to 12 carbons; Z is a benzoyl group, a radical of the formula --SO 2 C 6 H 5 or --SO 2 C 6 H 4 --CH 3 , and M is an alkali metal or ammonium.
| 2
|
BACKGROUND OF THE INVENTION
[0001] The present invention concerns toiletries like soap for hand, body and surface use, as well as other cleaning products.
[0002] The amount of time needed to clean the skin or a surface has been researched extensively. The Association for Professionals in Infection Control and Epidemiology (APIC) Guideline for Hand Washing and Hand Antisepsis in Health - Care Settings (1995) (Table 1), recommends a wash time of 10-15 seconds with soap or detergent for routine hand washing for general purposes. The APIC recommends an antimicrobial soap or detergent or alcohol-based rub wash for 10-15 seconds to remove or destroy transient micro-organisms in for example, nursing and food preparation applications. The APIC further recommends an antimicrobial soap or detergent with brushing for at least 120 seconds for surgical applications. The US Centers for Disease Control and Prevention (CDC) recommends up to 5 minutes of hand cleaning for surgical applications. Clearly, the length of time spend washing the hands can have a great effect on eradication of microbes. Thus there is a need for a cleaning formulation that will enable the user to judge how long he has washed his hands in order to comply with the guidelines.
[0003] Proper hand washing habits are important for children also. Children in particular need guidance in determining the appropriate amount of time hand washing should be performed. This guidance is generally given by parents or other caregivers and, while important, is not omni-present. In addition to parental guidance, various other mechanisms have been used to encourage longer hand washing times in children. Soaps have been formulated as foams, for example, to increase the enjoyment children find in hand washing and thus to increase the amount of time children spend in washing. Fragrances have also been used to make the hand washing experience more enjoyable. Dual chamber vessels have been used to produce a color change upon the mixing of the components. It has also been suggested that the reactants in the dual chamber system may alternatively be kept together with one component inactive by some means, such as by microencapsulation, until sufficient physical stimulus results in their effective mixing, or that the components be kept separate yet in one container through the use of a non-miscible mixture of two phases. These methods, though possible, are somewhat impractical and expensive. Far simpler would be a system that produces a color change which does not rely on a physical or phase separation to keep the components unmixed.
[0004] There is a need for a color changing toiletry or cleaning product that will provide a time delayed indication that a predetermined cleaning interval has passed after dispensing. There is a further need for a toiletry that is also fun for children to use. There is a further need for the color changing chemistry to be made from components that may be pre-mixed and packaged together for later dispensing from a single chamber vessel.
SUMMARY OF THE INVENTION
[0005] In response to the difficulties and problems encountered in the prior art, a new composition has been developed which contains a base material and an indicator or color change agent that provides a change detectible by a user some time after dispensing, and which is stable in a single phase and suitable for storage in a single chamber dispenser. The detectible change may occur in from a finite time to at most about 5 minutes after dispensing, though the change generally does not occur until a second or more after dispensing. The change may occur in at between about 1 second and about 120 seconds, or more desirably between about 5 seconds and about 45 seconds, or still more desirably between about 15 and 35 seconds. The color change may occur in about 10 seconds. This color change composition may be added to toiletries such as soaps, skin lotions, colognes, sunscreens, shampoos, gels, toothpastes, mouthwashes and so forth as well as to other cleaning products like surface cleaners and medical disinfectants.
[0006] In another aspect, the invention includes a dispenser having a storage chamber and a dispensing opening in liquid communication therewith, and a cleaning composition within the storage chamber. The cleaning composition is a single phase mixture of a surfactant, a reactant and a dye and the cleaning composition changes color after being dispensed.
[0007] This invention also encompasses a hygiene teaching aid and a method of developing a hygiene habit. The hygiene teaching aid has an indicator that provides a change detectible to a user after a period of time after dispensing has passed. The method of developing a hygiene habit includes the steps of dispensing soap and water into a user's hands, rubbing the hands together until a change detectible to the user is detected, and washing the hands with water, where the soap contains an indicator that provides the change after a period of time after dispensing the soap into the hands has passed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a drawing of a pump type liquid soap dispenser.
[0009] FIG. 2 is a drawing of a foaming liquid soap dispenser using a pump.
[0010] FIG. 3 is a drawing of a pliable storage bottle for liquid soap which may be inverted for soap dispensing.
[0011] FIG. 4 is a drawing of a non-pliable, manually openable storage container for liquid soap.
[0012] FIG. 5 is a drawing of a pump type liquid soap dispenser suitable for wall mounting.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The invention includes a base or carrier material such as a toiletry or cleaning product, and an indicator that provides a detectible change after a period of time, and that may be stably kept before use in a single closed vessel. It contains at least one dye or pre-dye and a modifying agent that causes a detectible change to occur. The detectible change may be, for example, in color or in shade or degree of color and changes in color may be from colorless to colored, colored to colorless, or from one color to another.
[0014] One method of producing the color change effect of this invention is by using color changing electrochemistry based on a reduction/oxidation or redox reaction, in the presence of a dye that is sensitive to this reaction; a redox dye. This reaction involves the transfer of electrons between at least one element or substance and another. In a redox reaction the element that loses electrons increases in valency and so is said to be oxidized and the element gaining electrons is reduced in valency and so is said to be reduced. Conversely, an element that has been oxidized is also referred to as a reducing agent since it must necessarily have reduced another element, i.e., provided one or more electrons to the other element. An element that has been reduced is also referred to as an oxidizing agent since it must necessarily have oxidized another element, i.e., received one or more electrons from the other element. Note that since redox reactions involve the transfer of electrons between at least two elements, it is a requirement that one element must be oxidized and another must be reduced in any redox reaction.
[0015] Reduction potential refers to the voltage that a redox reaction is capable of producing or consuming. Much effort has gone into the compilation of reduction potential for various redox reactions and various published sources, such as “Handbook of Photochemistry” by S. Murov, I. Carmichael and G. Hug, published by Marcel Dekker, Inc. N.Y. (1993), ISBN 0-8247-7911-8, are available to those skilled in the art for this information. The invention uses a reducing agent with sufficient redox potential to reduce a dye to a colorless state. Thus in the absence of such a reducing agent the dye, and by extension the base material, would remain the same color before and after use. A successful redox reaction for the practice of the invention should use components having a potential in the range of +0.9 to −0.9 volts. Oxygen, for example, has a redox potential of +0.82 volts.
[0016] Oxygen is poorly soluble in water and other materials like, for example, liquid soap formulations. There is normally, therefore, insufficient oxygen in the liquid to oxidize the colorless dye back to the colored state. It is known that the maximum concentration of oxygen in water at room temperature is approximately 13 parts per million (ppm), and, in the practice of the invention, this trace amount is consumed rapidly by the vastly greater amount of reducing agent. As a result, in a stationary, capped bottle, the dye in the liquid formulation will remain in the reduced or colorless state. When a small amount of the liquid formulation is used by placing it on the hands and by hand-washing action, for example in the case of hand soap, it is spread over a large surface area of the skin. This causes the oxygen concentration in this very thin film coating to exceed the concentration that the reducing agent can handle, allowing the dye to be oxidized and the color to develop in the desired indicator time period. Adjusting the concentration of the reducing agent and dye allows the modification of the desired time period from dispensing to color change.
[0017] This phenomenom is also observable by vigorously shaking a closed containing having a base material, such as a liquid soap formulation, and the color change indicator of this invention. When this is done, a color is developed due to the increased concentration of oxygen in the liquid soap. This color dissipates slowly after the container is allowed to rest as the oxygen slowly leaves the liquid soap. The reducing agent eventually overcomes the oxygen concentration in the liquid soap and reduces the oxidized dye back to the colorless state.
[0018] In one aspect of the invention, therefore, a redox reaction is triggered when the base material containing the color change composition of this invention is mixed with the air. It is the reaction with the oxygen in the air that is the primary reaction that begins the color change. In the case of a liquid hand soap, as discussed above for example, the action of rubbing the hands together results in mixing air into the soap to begin the reaction. In the redox reaction with oxygen, the oxygen is reduced and the dye is oxidized. As shown below (e.g. Example 1), this primary redox reaction results in a direct change in color, such as those reactions using a reducing agent and dye where the dye is a redox dye. When the color change composition is in storage, the redox dye is kept in its unoxidized state by the action of the reducing agent reacting with the available oxygen. Once the composition is in contact with an excess of oxygen such as when it is dispensed, the reducing agent is exhausted through oxidation and the redox dye then takes part in the oxidation, producing the color change.
[0019] This aspect of the invention, as discussed above, includes a redox dye and a reducing agent. These components are elaborated upon as follows:
[0020] Redox Dyes
[0021] Redox dyes include but are not limited to Food Blue 1, 2 and Food Green 3, Basic Blue 17, resazurin, FD&C Blue No. 2, FD&C Green No. 3, 1,9-dimethyl methylene blue, and saframine O, Suitable dyes include but are not limited to members of the thiazine, oxazines, azine and indigo dye classes. Other redox dye candidates have been identified allowing the following color changes to occur with this system:
[0000]
Colorless to blue
Basic Blue 17
Colorless to red
Resazurin (low dye concentration)
Yellow (similar in color to
FD&C Green No. 3
Dial liquid soap) to green
Yellow to purple
1,9-dimethyl methylene blue
Yellow to red
Resazurin (higher dye conc.)
Yellow to pink
Saframine O
[0022] Food grade dyes were evaluated as dye candidates in the reducing agent/redox dye color change liquid soap formulation and a variety of color changing chemistries are available. The results of this evaluation may be seen in Example 6.
[0023] The amount of dye used in the practice of the invention is desirably between about 0.001 and 0.5 weight percent, more desirably between about 0.002 and 0.25 weight percent dye and still more desirably between about 0.003 and 0.1 weight percent.
[0024] Reducing Agents
[0025] Reducing agents include but are not limited to any compound that is compatible with the redox dye and base material being used and which will react with oxygen in a redox reaction. Upon mixing the base material, dye and reducing agent, the reducing agent reduces the dye to the colorless “reduced dye”. The base material will generally have a small amount of dissolved oxygen already present, and this oxygen reacts (oxidizes) with the “reduced dye” to form the colored dye. This is quickly re-converted back to the reduced form (colorless) by the high concentration of the reducing agent present in the formulation. The oxygen is therefore consumed in the formulation and converted, eventually, to water. The formulation therefore has essentially no oxygen present in it. This equilibrium may be represented as follows:
[0000]
[0026] In the case of a liquid soap formulation, for example, on dispensing the soap onto the hand(s) and conducting hand-washing action, the soap is spread out over the hands as a thin layer and diluted with water. This action allows atmospheric oxygen to penetrate this thin layer and oxidize the dye to the colored state. The reducing agent reduces this dye to an extent but is eventually overwhelmed by the excess amount of atmospheric oxygen introduced by virtue of the large exposed surface area, and is consumed, allowing the dye to remain colored. This color formation gives the visual indication that sufficient hand-washing time has occurred. The “battle” of oxygen against reducing agent for the dye takes a finite time, thus allowing control of the hand-washing period for indicating purposes.
[0027] When a liquid soap formulation containing the inventive composition in a container is shaken, oxygen is introduced into the soap. The oxygen converts the colorless “reduced dye” to the colored form, but due to the solubility of oxygen in water being only about 13 parts per million (ppm) the oxygen is rapidly consumed in converting some of the dye. This colored oxidized dye is reduced by the larger concentration of reducing agent and the soap quickly becomes colorless once more. With repeated vigorous shake-cycles it may be possible to consume the reducing agent entirely, in which case the soap would remain colored.
[0028] Reducing agents suitable for producing a redox reaction upon exposure to the oxygen in air include but are not limited to sugars like glucose, galactose and xylose and so forth. Other suitable reducing agents include but are not limited to hydroquinone, ascorbic acid, cysteine, dithionite, ferric ion, copper ion, silver ion, chlorine, phenols, permanganate ion, glucothione, iodine and mixtures thereof. Metal complexes that can function as reducing agents are also suitable for the practice of this invention. Metal complexes include but are not limited to mononuclear, binuclear and cluster complexes like iron protoporyphyrin complexes and iron-sulfur proteins.
[0029] The reaction rates are different for the same amount by weight of different reducing agents and this may be an additional method of modifying the color change to the desired time period. Various sugars were evaluated as reducing agents and the results of this evaluation may be seen in Example 6.
[0030] The amount of reducing agent used in the practice of this invention is desirably between about 0.1 and 2.0 weight percent, more desirably between about 0.2 and 1.50 weight percent and still more desirably between about 0.3 and 1 weight percent. It is also desirable that the ratio of reducing agent to redox dye be at least about 2 to 1, more desirably at least about 5 to 1 and still more desirably at least about 10 to 1.
[0031] In another aspect of the invention, the primary redox reaction begun with contact with air may then initiate a secondary reaction that results in a color change. An example of this aspect is shown in Example 2. The primary reaction between a reducing agent and the air may, for example, result in a change in pH of the solution. The change in pH may then cause a color change through the use of pH sensitive dyes like those described in, for example The Sigma - Aldrich Handbook of Stains, Dyes and Indicators by the Aldrich Chemical Company (1990), ISBN 0-941633-22-5, at the inside back cover. Catalysts and buffers may also be used to control the reaction kinetics. The components of this aspect of the invention are discussed immediately below.
[0032] PH Sensitive Dyes
[0033] Suitable dyes may be activated between about the pHs of 4 and 9 or more particularly 5 and 8 for normal use on the human body and may thus be paired with the primary redox reactants in such a way as to produce the most effective color change. Suitable pH sensitive dyes include but are not limited to carminic acid, bromocresol green, chrysoidin, methyl red/Na salt, alizarin red S, cochineal, chlorphenol red, bromocresol purple, 4-nitrophenol, alizarin, nitrazine yellow, bromothymol blue, brilliant yellow, neutral red, rosolic acid, phenol red, 3-nitrophenol, orange II and so forth.
[0034] The amount of dye used in the practice of the invention should be between about 0.001 and 0.5 weight percent, more desirably between about 0.002 and 0.25 weight percent dye and still more desirably between about 0.003 and 0.1 weight percent.
[0035] Catalysts
[0036] The use of a catalyst, as the term is commonly understood in the scientific community, increases the ability of the designer to control the speed of the reaction by selecting the type and amount of catalyst present. An example of a catalyst is an enzyme, e.g.; glucose oxidase. The catalyst produces a change in the pH of the solution upon reaction with air (oxygen), which subsequently produces a color change through the use of a pH sensitive dye. An example of the effect of catalysts on the reaction is shown in Example 2. If a catalyst is used it may be present in an amount between about 0.001 and 0.5 weight percent.
[0037] PH Buffering
[0038] pH buffering is commonly used in chemical reactions to control the rate of reaction. In the case of the invention, a pH buffer may be used for this purpose as well as to increase the stability of the mixture in storage and transportation. The buffering capacity may be designed to be sufficient for any pH change induced by the relatively small amount of oxygen contained within the solution or in the “headspace” above the solution in the storage container, yet below that needed for buffering of the solution when exposed to large amounts of oxygen as occurs during use. Suitable pH buffers include but are not limited to sodium laureth sulfate and citric acid, and so forth. Selection of one or more buffering agents, however, would be dependent upon the reactants used, the choice of dye and the catalyst used, if any, and are within the ability of those skilled in the art to select.
[0039] In yet another aspect of the invention, the color change caused by both the redox dye and the pH sensitive dye compositions may be used together in the same solution. More than one reducing agent may also be employed to initiate the color change-producing redox reaction with the oxygen in the air.
[0040] The amount of time between dispensing and color change will depend on the formulation used as well as the energy used to introduce oxygen to the solution. Dispensing a color change soap solution onto the hands, followed by vigorous hand rubbing, for example, will result in a more rapid color change than would less vigorous hand rubbing. Reducing the amounts of dye and other components will likewise result in lengthening the time to the color change. Relatively simple experimentation with the amounts and types of soap, dye and other components discussed herein allows one to design a color change composition that will change color in a length of time up to about 5 minutes.
[0041] It is believed that the reversible color change feature of the invention would provide a fun and play aspect to a single chamber liquid soap. Each change of color from its starting color to a second color and back to the starting color is a “cycle” and it should also be noted that the color change cycle is dependent on the dye concentration. In the laboratory experiments discussed herein, the number of color change cycles possible ranged from 12 cycles to 35 cycles, depending on the dye concentration.
[0042] Dispensers
[0043] The indicator composition of the invention may be dispensed with, for example, liquid soap, in a number of different ways. One particular example is by the use of the liquid pump type dispenser, as illustrated in FIG. 1 . This dispenser contains soap 8 , has a lower intake member 10 , a central pump assembly 12 and an outlet member 14 . The lower intake member 10 extends downward into a supply container 16 for liquid soap 8 storage to a point near the bottom 18 . The lower intake member 10 within the supply container 16 is shown in dashed lines. The central pump assembly 12 has a check-valve and spring arrangement (not shown) which allows the one-way movement of liquid soap 8 through the pump assembly 12 . When a user pushes down on the upper outlet member 14 , the pump assembly 12 is actuated, moving liquid soap 8 upwardly from the supply container 16 , through the intake member 10 and pump assembly 12 and discharging it from the outlet member 14 .
[0044] It is believed that any of numerous dispensing mechanisms can be used with the present invention. As a further example is a foaming pump dispenser, such as, for example, described in U.S. Pat. No. 6,446,840. In reference to FIG. 2 , a foaming dispenser has a lower intake member 20 , a central pump assembly 22 , and an upper outlet member 24 . The intake member 20 has an open intake tube 26 extending into the liquid soap during normal operation, and connected to a lower extension 28 forming a liquid chamber 30 projecting from a housing 32 . A check-valve 34 permits flow only up into the chamber 30 from the tube 26 . The central pump assembly 22 has a foam-generating nozzle which, when pressurized with a liquid on one sides emits on the opposite side a swirling aerosol spray. Axial passages and radial ports allow air flow from the chamber 36 into the chamber 38 . The foaming chamber 38 holds a foam generator. The housing 32 is designed to sit on the rim of a supply container holding a body of liquid foamable soap or detergent.
[0045] Still another dispenser is seen in FIG. 3 . In this dispenser, the supply container 40 is pliable and is fitted with a valve 42 . Withdrawal of liquid soap 8 is accomplished by opening the valve 42 , inventing the dispenser, and squeezing the supply container 40 to force soap through the valve 42 and onto, for example, the hands.
[0046] Still another dispenser is shown in FIG. 4 and in which the supply container 50 is non-pliable. The supply container 50 is fitted with a removable top 52 which may be unscrewed from the supply container 60 so that liquid soap 8 may be removed manually by a user.
[0047] Yet another example of a dispenser is commonly used in wall mounting installations. This dispenser is depicted in FIG. 5 and described in U.S. Pat. No. 6,533,145 and U.S. Design Pat. No. 388,990, the contents of which are hereby incorporated by reference as if set forth in their entirety, and has a supply container 60 , a central pump assembly 62 and an outlet part 64 . Similarly to the pump dispenser of FIG. 1 , the central pump assembly 62 has a check-valve and spring arrangement (not shown) which allows the one-way movement of liquid soap through the pump assembly 62 . When a user pushes on the outlet part 64 , the pump assembly 62 is actuated, moving liquid the supply container 60 , through the pump assembly 62 and discharging it from the outlet part 64 . In various aspects of the inventions, the outlet part 64 may be located below the supply container 60 and the pump assembly 62 may be recessed within the supply container 60 .
[0048] Base Materials
[0049] The color change composition of the invention is suitable for addition to base materials such as toiletries. Toiletries include but are not limited to soaps (liquid and bar), skin lotions, colognes, sunscreens, shampoos, gels, toothpastes, mouthwashes and the like.
[0050] Base materials further include but are not limited to cleaning products such as hard surface cleansers and medical disinfectants. Hard surface cleansers incorporating the color change chemistry of the invention may be used in the home or business environment in, for example, food preparation areas. In such uses, the time from application to color change may be adjusted to provide effective microbial elimination. Likewise, medical disinfectants using the color change indicator of this invention can let a user know when a time sufficient for effective microbial control has elapsed.
[0051] Many toiletries and cleaners contain similar core ingredients; such as water and surfactants. They may also contain oils, detergents, emulsifiers, film formers, waxes, perfumes, preservatives, emollients, solvents, thickeners, humectants, chelating agents, stabilizers, pH adjusters, and so forth. In U.S. Pat. No. 3,658,985, for example, an anionic based composition contains a minor amount of a fatty acid alkanolamide. U.S. Pat. No. 3,769,398 discloses a betaine-based composition containing minor amounts of nonionic surfactants. U.S. Pat. No. 4,329,335 also discloses a composition containing a betaine surfactant as the major ingredient and minor amounts of a nonionic surfactant and of a fatty acid mono- or di-ethanolamide. U.S. Pat. No. 4,259,204 discloses a composition comprising 0.8 to 20% by weight of an anionic phosphoric acid ester and one additional surfactant which may be either anionic, amphitricha, or nonionic. U.S. Pat. No. 4,329,334 discloses an anionic amphoteric based composition containing a major amount of anionic surfactant and lesser amounts of a betaine and nonionic surfactants.
[0052] U.S. Pat. No. 3,935,129 discloses a liquid cleaning composition containing an alkali metal silicate, urea, glycerin, triethanolamine, an anionic detergent and a nonionic detergent. The silicate content determines the amount of anionic and/or nonionic detergent in the liquid cleaning composition. U.S. Pat. No. 4,129,515 discloses a liquid detergent comprising a mixture of substantially equal amounts of anionic and nonionic surfactants, alkanolamines and magnesium salts, and, optionally, zwitterionic surfactants as suds modifiers. U.S. Pat. No. 4,224,195 discloses an aqueous detergent composition comprising a specific group of nonionic detergents, namely, an ethylene oxide of a secondary alcohol, a specific group of anionic detergents, namely, a sulfuric ester salt of an ethylene oxide adduct of a secondary alcohol, and an amphoteric surfactant which may be a betaine, wherein either the anionic or nonionic surfactant may be the major ingredient. Detergent compositions containing all nonionic surfactants are shown in U.S. Pat. Nos. 4,154,706 and 4,329,336. U.S. Pat. No. 4,013,787 discloses a piperazine based polymer in conditioning and shampoo compositions. U.S. Pat. No. 4,450,091 discloses high viscosity compositions containing a blend of an amphoteric betaine surfactant, a polyoxybutylenepolyoxyethylene nonionic detergent, an anionic surfactant, a fatty acid alkanolamide and a polyoxyalkylene glycol fatty ester. U.S. Pat. No. 4,595,526 describes a composition comprising a nonionic surfactant, a betaine surfactant, an anionic surfactant and a C12-C14 fatty acid mono-ethanolamide foam stabilizer. The contents of the patents discussed herein are hereby incorporated by reference as if set forth in their entirety.
[0053] Further information on these ingredients may be obtained, for example, by reference to: Cosmetics & Toiletries , Vol. 102, No. 3, March 1987; Balsam, M. S., et al., editors, Cosmetics Science and Technology, 2nd edition, Vol. 1, pp 27-104 and 179-222 Wiley-Interscience, New York, 1972, Vol. 104, pp 67-111, February 1989 ; Cosmetics & Toiletries , Vol. 103, No. 12, pp 100-129, December 1988, Nikitakis, J. M., editor, CTFA Cosmetic Ingredient Handbook , first edition, published by The Cosmetic, Toiletry and Fragrance Association, Inc., Washing-ton, D.C., 1988, Mukhtar, H, editor, Pharmacology of the Skin , CRC Press 1992; and Green, F J, The Sigma - Aldrich Handbook of Stains, Dyes and Indicators ; Aldrich Chemical Company, Milwaukee Wis., 1991, the contents of which are hereby incorporated by reference as if set forth in their entirety.
[0054] Exemplary materials that may be used in the practice of this invention further include but are not limited to those discussed in Cosmetic and Toiletry Formulations by Ernest W. Flick, ISBN 0-8155-1218-X, second edition, section XII (pages 707-744).
[0055] These include but are not limited to for example, the following formulations:
[0000]
wt %
Liquid hand soap
EMERY 5310 coconut sulfosuccinate
20
EMERSAL 6400 sodium lauryl sulfate
10
EMID 6513 lauramide DEA
3
EMID 6540 linoleamide DEA
2
ETHOXYOL 1707 emulsifying acetate ester
1
EMERSOL 233 oleic acid
1
EMERESSENCE 1160 rose ether phenoxyethanol
1
Triethanolamine
0.5
Deionized water
balance
Liquid soap
Ammonium laureth sulfate, 60%
24
Cocamidopropyl betaine
6
Stearamidopropyl dimethylamine
1.5
Sodium chloride
1.3
Glycol distearate
1
Citric acid
0.25
Methylparaben
0.15
Propylparaben
0.05
Bronopol
0.05
Water
balance
Bar soap
Soap base 80/20
95.68
Water
1
Antioxidant
0.07
Perfume oil
0.75
Titanium dioxide
0.5
GLUCAM E-20
2
EXAMPLES
Example 1A
Redox Dye/Reducing Agent Producing Color Change
[0056] The formulation used was: 200 grams of Kimberly-Clark Professional antibacterial Clear Skin Cleanser (PCSC C2001-1824), 0.01 gram of Food Blue No. 2 dye and 1.2 grams of glucose sugar. In weight percentage this was 0.005 weight percent dye and 0.6 weight percent sugar and the balance soap. The mixture was stirred at ambient temperature for 20 minutes to dissolve additives and then poured into a dispenser container. On standing, the color turned a pale yellow color.
[0057] In this example, Indigo Carmine (Food Blue No. 2, FD&C No. 1) dye, normally blue/green in color, when mixed into a glucose/liquid soap solution, was reduced by the glucose to a pale yellow color. On exposure of the soap mixture to the air and with rubbing on the hands, oxygen oxidized the dye back to the green/blue color in about 10 to 20 seconds. Interestingly, there is not enough oxygen in the soap while sealed in a container to oxidize the reduced dye, thereby allowing it to remain yellow in the container.
[0058] As a variation of this Example 1A, a number of additional Examples 1B-1G were conducted with the same ingredients in different proportions and the time to initial color change noted. These examples used a soap solution of 500 ml of Kimberly-Clark Professional antibacterial Clear Skin Cleanser with 9 grams of glucose and a dye solution of 0.2 grams of Food Blue No. 2 in 100 ml of water, Samples were prepared by placing the dye solution in the amounts below into 100 ml beakers and adding the soap solution to make a total volume of 20 ml. Example 1G used 10 ml of the soap and glucose solution with another 9 ml of only soap, with 1 ml of dye solution.
[0000]
Glucose Stock
Dye Stock
Solution (ml)
Solution (ml)
Ex-
(gram of glucose)
(mg of dye)
time
ample
17 (0.170 g)
3 (6 mg)
<5
sec
1B
18 (0.180 g)
2 (4 mg)
5-10
sec
1C
19 (0.190 g)
1 (2 mg)
15-20
sec
1D
19.5 (0.195 g)
0.5 (1 mg)
40-50
sec
1E
19.75 (0.198 g)
0.25 (0.5 mg)
2 min +/− 10 sec
1F
10 plus 9 ml soap (0.10 g)
1 (2 mg)
15-20
sec
1G
[0059] Tailoring the time for initial color change can be seen therefore to be a relatively straight forward matter within the range of normal experimentation.
Example 2
pH Change Producing Color Change
[0060] The formulation used was: 76 grams of Kimberly-Clark Professional antibacterial Clear Skin Cleanser (PCSC C2001-1824), 1 gram of glucose oxidase enzyme catalyst and a trace amount of chlorophenol red (the initial mixture), followed by the addition of 6.4 milligrams of glucose sugar to 4.7 grams of the initial mixture. The initial mixture remained red upon mixing and after the addition of the glucose (the final mixture). The final mixture was placed on a tile and spread manually, resulting in a gradual color change to yellow in about 20 seconds.
[0061] This example of pH change producing a color change is the addition of a glucose enzyme catalyst and chlorophenol red to a soap solution. After mixing, glucose, having a redox potential of −0.42v, was added and the color (red) did not change. Upon agitation in air on a surface, however, sufficient oxygen was introduced to react the glucose, in the presence of the catalyst, to gluconic acid and so reduce the pH of the solution below 6, inducing a color change caused by the chlorophenol red.
Example 3
Redox Dye/Reducing Agent Producing Color Change Using Cysteine/Ascorbic Acid
[0062] Reagent stock solutions were made having the following compositions:
[0063] 2.0 grams of Indigo Carmine (Food Blue 1, FD&C Blue 2) redox dye dissolved in 1000 ml of tap water. Indigo Carmine dye is available from the Aldrich Chemical Company of Milwaukee Wis., catalog number 13,116-4.
[0064] 10 weight percent L-ascorbic acid reducing agent in tap water. Ascorbic acid is available from the Aldrich Chemical Company, catalog number 25,556-4.
[0065] 10 weight percent DL-cysteine reducing agent in tap water. Cysteine is available from the Aldrich Chemical Company, catalog number 86,167-7.
[0066] A series of water solutions were made with 1 ml of Indigo Carmine dye reagent stock solution and made up to 100 ml with tap water. Various amounts of the other two reagent stock solutions were added to this dye solution as shown below. After being shaken to initiate the color change, the compositions were then allowed to equilibrate and were timed for the reverse color change (to colorless) and tested for pH as indicated.
[0000]
REAGENT
Volume (ml) of Reagent Stock Solution Added
Cysteine
0
0
0
0
1
5
10
20
1
5
10
20
Ascorbic Acid
1
5
10
20
0
0
0
0
1
5
10
20
Time To Colorless
NC
NC
NC
NC
90
130
260
?
260
45
25
10
(min)
pH
6.4
6.4
6.1
6.0
6.4
6.2
6.1
5.9
6.4
6.3
6.2
6.0
NC = No change in color after 19 hours.
? = Turned colorless sometime after 3 hours and before 19 hours.
[0067] The cysteine/ascorbic acid solution was tested in liquid soap formulations (PCSC C2001-1824) as well. The water solutions of the reagent stock solutions were added directly to 50 mls of liquid soap in the amounts indicated below. The compositions were again shaken and then allowed to equilibrate and the time to reverse the change color and the pH tested as reported.
[0000]
SAMPLE
Volume (ml) of Reagent Stock Solution Added
Dye
1
3
1
1
3
Ascorbic Acid
0
0
9
20
20
Cysteine
0
0
9
20
20
Time to colorless
NC
NC
120
60
90
(min)
pH
6.7
6.7
6.1
6.0
6.0
[0068] The blue to colorless change is reversible by shaking the liquid to introduce oxygen, which oxidizes the dye back to the blue color in about 20 seconds.
[0069] As can be seen from these results, the cysteine/ascorbic acid system can be used to formulate a color changing liquid soap with Indigo Carmine dye. Cysteine alone also causes a reversible decolorization reaction to occur, but the reaction rate is much slower. In addition, substitutes known to those skilled in the art may be used for these reagents. Cysteine, for example, may substituted with glutathione, though the color change is somewhat slower. Indigo carmine dye may be substituted with 1,9 dimethyl methylene blue (thiazine dye class) and brilliant cresyl blue acid (thazine dye class).
Example 4
Redox Dye/Reducing Agent Producing Color Change
[0070] The formulation used was: 200 grams of Kimberly-Clark Professional Moisturizing Instant Hand Antiseptic as given above, 0.01 gram of Food Blue No. 2 dye and 1.2 grams of glucose sugar. On handwashing, the color turned from colorless to blue in about 10 to 20 seconds.
Example 5
Redox Dye/Reducing Agent Producing Color Change
[0071] The formulation used was: 200 grams of Kimberly-Clark Professional Eurobath Foaming Soap (P8273-PS117-81.102), 0.01 gram of Food Blue No. 2 dye and 1.2 grams of glucose sugar. After mixing the ingredients, the white foam was place on the hand and with handwashing action the soap changed from white to blue. The foaming dispenser, as discussed above, also introduced enough oxygen to the soap upon dispensing that the soap changes color even without agitation in approximately 10 to 20 seconds.
Example 6
Redox Dyes Producing Color Change
[0072] The dyes were evaluated by preparing the formulation in Example 1A using the corresponding dye, washing the hands with running water, and grading the color and time to change. The following results were obtained.
[0000] Food Dye Color in Soap Color on Use Evaluation Blue 1 Yellow Blue Works Blue 2 Yellow Blue Works Red 40 Yellow Yellow Fails Green 3 Yellow Green Works Yellow 5 Yellow Yellow Fails
The study showed that Food Blue 1, 2 and Food Green 3 all work well in the liquid soap formulation.
Example 7
Evaluation of Simple Sugars
[0073] A side-by-side study was carried out to examine the effect of substituting various simple sugars on the time taken for the color to revert back to the pale yellow. (Food blue No. 2 was used as the dye.) It should be noted that the reaction of oxygen from the air to convert the colorless (or pale yellow) soap into a colored liquid during handwashing is very rapid. Thus, to study the reducing power of the various sugars the soap/dye solutions were shaken and the time taken to revert to colorless/pale yellow determined. The results are shown below:
[0000]
Sugar
Time (Seconds)
Glucose
100
Xylose
80
Galactose
120
Sucrose
No change
[0074] As will be appreciated by those skilled in the art, changes and variations to the invention are considered to be within the ability of those skilled in the art, Examples of such changes are contained in the patents identified above, each of which is incorporated herein by reference in its entirety to the extent it is consistent with this specification. Such changes and variations are intended by the inventors to be within the scope of the invention.
|
There is provided a color change composition that remains stable in a single phase and that contains an indicator that produces an observable color change after a period of time to show that sufficient cleaning has been done or to indicate the thoroughness of the cleaning. This use indicating color change is useful for, for example, in soap for teaching children to wash their hands for a sufficient period of time. This composition may be added to many different base materials to indicate time of use or as a way to introduce enjoyment to the activity.
| 2
|
This application is a continuation of application Ser. No. 07/981,733 filed Nov. 25, 1992, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a combustion knock detection system provided in an internal combustion engine and more particularly to a combustion knock detection system provided in an internal combustion engine incorporated with the so-called traction control system.
2. Description of the Prior Art
In a conventional knock detection system proposed hitherto such as disclosed in a U.S. Pat. No. 5,165,378 by the assignee, a knock sensor is provided at an internal combustion engine to detect a combustion knock which can occur in the engine. In the known system, the vibration of the engine is detected by the sensor at a range of crankshaft angles during which no combustion occurs to determine a reference noise level. Then, the vibration of the engine detected at a second range of crankshaft angles during which combustion occurs so that knock could occur, is compared with the reference noise level. If the vibration detected at the second crank-shaft angle range is found to exceed the reference noise level, it is determined that knock occurs.
More specifically, as illustrated in FIG. 11(a), in crankshaft angles between TDC (top dead center) positions, which are 120 degrees if the engine has six cylinders, the output of the knock sensor becomes great immediately after each TDC position when a combustion occurs as illustrated in FIG. 11(b). Therefore, two gates, named a "noise gate" and a "knock gate", which are corresponding to the aforesaid first and second ranges of crankshaft angles are prepared as shown in (c) of the same figure. The sensor output in the noise gate is averaged to obtain a noise level VNIS and is then multiplied by an amplification gain (factor) AG and a coefficient K which varies with an engine coolant temperature or manifold pressure or the like, to determine the reference noise level KLVL as follows;
KLVL=AG×K×VNIS
Then the sensor output in the knock gate is compared with the reference noise level KLVL in a circuit which produces a pulse each time the sensor output in the knock gate exceeds the reference noise level as illustrated in FIG. 11(d) and (e). The number of pulses is then counted ("3" in the example) and if the counted values have been found to exceed a predetermined reference number, it is determined that a combustion knock occurs.
Apart from the above, recent years have seen increasing traction control systems, referred to as "TCS" hereinafter, in which the engine output torque is forcibly reduced if a driven wheel of the vehicle on which the engine is mounted is found to be slipped or spun, so as to lower the torque given to the wheel and to finally prevent the wheel from slipping or spinning excessively. The engine output torque reduction for the purpose is carried out by adjusting ignition timing in the retard direction, by adjusting an air-fuel ratio in a lean mixture or by discontinuing supply of the fuel to one or more cylinders.
In the TCS, when it operates, the ignition timing retardation or fuel cut and the like will therefore be carried out so that the mechanical vibration of the engine becomes great due to the sudden change in the engine output torque. For that reason, if a combustion knock is to be detected in the manner earlier mentioned, the knock sensor output in the knock gate will become great and there could be a possibility of erroneously detecting a combustion knock. In other words, a combustion knock could be detected although it does not exists actually, which could be a bar for a knock control.
SUMMARY OF THE INVENTION
This invention was accomplished in the light of the aforesaid problem and has its object to provide a combustion knock detection system for an internal combustion engine in which a presence/absence of a combustion knock can be detected accurately when the system is incorporated with the TCS.
For realizing the object, the present invention provides a system for detecting a combustion knock occurred in an internal combustion engine, including a knock sensor, a first device for receiving an output of the sensor detected within a range of crankshaft angles during which a combustion knock could occur, a second device for establishing a reference level, and a third device for determining occurrence of a combustion knock by comparing the output of the sensor detected within the range of crankshaft angles with the reference level. In the system, the improvement comprises a fourth device for detecting a slipping condition of a driven wheel of a vehicle on which the engine is mounted to control the slipping condition of the driven wheel and the second device changes the reference level when the fourth device controls the slipping condition of the driven wheel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an explanatory overall view of a combustion knock detection system for an internal combustion engine including a TCS (traction control system) according to the present invention;
FIG. 2 is a flow chart showing the operation of the TCS shown in FIG. 1 for determining if the traction control should be carried out;
FIG. 3 is a flow chart showing a main routine of the combustion knock detection system shown in FIG. 1;
FIG. 4 is a subroutine flow chart for calculating a reference level KLVL referred in FIG. 3 flow chart;
FIG. 5 is an explanatory view showing the characteristics of a map for retrieving an amplification gain (factor) AG referred in FIG. 4 flow chart;
FIG. 6 is an explanatory view showing the characteristics of a table for retrieving a coefficient KAGTW referred in FIG. 4 flow chart;
FIG. 7 is a subroutine flow chart for calculating a coefficient KAGTCS referred in FIG. 4 flow chart;
FIG. 8 is a subroutine flow chart, similar to FIG. 7, but showing a second embodiment of the present invention;
FIG. 9 is a tabular graph showing values KAGTCSn referred in FIG. 8 flow chart;
FIG. 10 is a graph showing the characteristics of the values KAGTCSn referred in FIG. 8 flow chart; and
FIGS. 11a-11e is an explanatory timing chart for detecting occurrence of a combustion knock according to a prior art detection system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the invention will now be explained with reference to the attached drawings.
In FIG. 1, reference numeral 10 designates a main unit of an internal combustion engine having DOHC in-line six cylinders. In the main engine unit 10, at a middle position of an air intake passage 12, a throttle body 14 is provided, in which a throttle valve 16 is installed. The throttle valve 16 is connected with a throttle position sensor 18 which generates an electric signal indicative of the opening degree of the throttle valve θTH and forwards to an electronic control unit 20 for controlling the engine, shown as "ECU" in the figure. The ECU 20 is made up of a microcomputer comprising an input circuit 20a, a CPU 20b, a memories 20c and an output circuit 20d.
A fuel injection valve 24 is provided in the air intake passage 12 downstream of the throttle valve 16 and immediately before an intake valve, not shown, of each cylinder, not shown. The fuel injection valve 24 is connected to a fuel pump, not shown, to be supplied with fuel and is further connected, in terms of electricity, with the ECU 20 to be controlled its opening period for injection. The air intake passage (manifold) 12 is branched off down-stream of the throttle valve and a manifold absolute pressure sensor 26 is provided at the branch designated by reference numeral 28. The manifold absolute pressure sensor 26 generates an electric signal indicative of a manifold absolute pressure PBA and sends it to the ECU 20. And, a manifold air temperature sensor 30 is provided in the proximity of the manifold absolute pressure sensor 26 to generate an electric signal indicative of a manifold air temperature TA and sends it the ECU 20.
A knock or detonation sensor 34 made of a piezo-electric material, is provided at a cylinder block, not shown, of the main engine unit 10 to detect an electric signal indicative of vibration KNOCK of the engine main unit 10 and sends it to the ECU 20. A coolant temperature sensor 36 is mounted in a water-filled jacket, not shown, in the cylinder block of the main engine unit 10 to generate and sends an electric signal indicative of a coolant temperature TW of the engine to the ECU 20.
A crankshaft sensor 40 is provided at a crank-shaft, not shown, to generate a pulse signal θCR once every predetermined crankshaft angle degrees including the TDC position and send it to the ECU 20 in which the signal is counted to detect an engine speed NE. Similar sensor 42 is provided to generate a pulse signal CYL once 720 crankshaft angles which is also sent to the ECU 20 to be used for identifying the position of each six cylinders. Each six cylinders is equipped with a spark plug 44 which is connected to the ECU 20 via an ignition system, not shown, and to be controlled its ignition timing.
Based on the outputs of the sensors, the ECU 20 determines the opening period of the fuel injection valve 24 and ignition timing of the engine. If a combustion knock is detected, the ECU 20 retards the ignition timing and then advances it when the combustion knock is ceased.
Reference numeral 50 designates another electronic control unit, referred to as "TCS ECU", which has wheel speed sensors 52, 54 for detecting speed VWL, VWR of a pair of driven wheels, not shown, and another pair of wheel speed sensors 56, 58 for detecting speed VL, VR of a pair of non-driven wheels, not shown. The TCS ECU 50 is also made up of a microcomputer and detects the slipping or spinning condition of the driven wheels in a manner described just below so as to determine if the engine output torque should be reduced. The TCS ECU 50 is connected with the first ECU 20 via a communication line and if the TCS ECU 50 determines the engine output torque reduction, the first ECU 20 carries out the reduction by retarding ignition timing and the like as aforementioned.
FIG. 2 is a flow chart showing the operation of the TCS ECU 50 to determine if the engine output torque should be reduced. The program is started at each TDC position.
The procedure begins with the first step S1 in which a slip ratio of the driven wheel is first calculated in accordance with an equation shown below using the left (or right) driven wheel speed and the left (or right) non-driven wheel speed: ##EQU1##
Control next passes to step S2 in which the calculated slip ratio is compared with a predetermined reference value so as to determine if the driven wheel slippage is excessive. If the calculated slip ratio is found to exceed the reference value so that the determination is affirmative, control passes to step S3 in which a bit flag TCS is set to one which indicates the engine output torque reduction should be carried out and if the flag is set, the first ECU 20 adjusts the air-fuel ratio in the lean direction, or adjusts ignition timing in the retard direction or discontinues fuel supply to one or more cylinders. Otherwise, control passes to step S4 in which the bit flag is set to zero and no engine output torque reduction is carried out in the first ECU 20.
FIG. 3 is a flow chart showing the main routine of the operation of the combustion knock detection system according to the invention. The program is started at each TDC position.
The procedure begins with step S10 in which the output KNOCK of the knock sensor 34 in the knock gate and noise gate is successively read out. Control then advances to step S12 in which the sensor output KNOCK in the knock gate is labeled as "KNOCKK" and that in the noise gate as "KNOCKN". Next, control passes to step S14 in which a reference level KLVL is calculated.
FIG. 4 is a flow chart showing a subroutine for calculating the reference level KLVL.
At its first step S100, an amplifier gain (factor) called "AG" is determined by retrieving a map using an engine speed NE and a manifold absolute pressure PBA as address data. FIG. 5 illustrates the characteristics of the map.
Control then moves to step S102 in which a correction coefficient for the amplifier gain KAGTW is determined by retrieving a table using a coolant temperature TW as address datum. FIG. 6 illustrates the characteristics of the table. As illustrated in FIG. 6, the correction coefficient decreases with increasing coolant temperature.
It should be noted here that the word "map" means a look-up table(s) to be retrieved by two parameters and the word "table" means a look-up table to be retrieved by a single parameter. In retrieving a value either from the map or table, whichever it may be, an interpolation is used if needed.
Returning to FIG. 4, control next passes to step S104 in which the noise level VNIS is determined. This is carried out by averaging the sensor output KNOCKN detected in the noise gate using a low pass filter having a predetermined time constant.
Control then passes to step S106 in which another correction coefficient KAGTCS for the amplifier gain is calculated.
FIG. 7 is a flow chart showing a subroutine for calculating the coefficient KAGTCS.
First in step S200, it is checked if the bit of the aforesaid flag FTC is one, i.e., the TCS operation is being carried out. If the answer is affirmative, control passes to step S202 in which the coefficient KAGTCS is determined to be a predetermined value KAGTCSX (1.5 for example). If the answer at step S200 is negative, control passes to step S204 in which the coefficient is determined to be 1.0, which means no correction is made.
Returning to FIG. 4, control passes to the final step S108 in which the reference level KLVL is determined by multiplying the noise level with the gain and the coefficients as illustrated.
Again returning to FIG. 3, control passes to step S16 in which the sensor output KNOCKK detected in the knock gate is compared with the reference level KLVL to determine the number of times (the knock pulses) NPn at which the sensor output KNOCKK exceeds the reference value KLVL.
Control then advances to step S18 in which the determined number NPn is compared with a reference value NPref (one for example). If the determined number NPn is found to exceed the reference value NPref, control passes to step S20 in which a knock control is carried out in an appropriate manner such as by retarding ignition timing. Alternatively if the determined number NPn is found, at step S18, to be less than the reference value NPrer, the program is immediately terminated.
With the arrangement, since the reference level KLVL is enlarged when the TCS operates, it can prevent the louder noise generated in the knock gate due to the sudden change in the engine output torque by the TCS operation from being detected as the occurrence of a combustion knock. The detection accuracy is enhanced and a knock control can be made in an appropriate manner.
FIG. 8 is a flow chart, similar to FIG. 7, but showing a subroutine for calculating the correction coefficient KAGTCS according to a second embodiment of the present invention.
In the flow chart, when it is confirmed at step S300 that the bit of the flag FTC is set to one, control passes to step S302 in which the coefficient KAGTCS1-5 is selected in response to the TCS operation level. To be more specific, as illustrated in a tabular graph in FIG. 9, five TCS operation levels TC1 to TC5 are predetermined, in response to the slip ratio 1 to 5 of the driven wheel. In the second embodiment, the engine output torque reduction is carried out by cutting fuel supply to a cylinder(s). That is; if the slip factor is small, i.e. "1", the TCS operation level is small (TC1) so that the fuel cut is carried out only for a single cylinder. The number of cylinders to be cut off from the fuel supply will increasing with increasing slip factor and hence with increasing TCS operation level. At its maximum (TC5), the whole six cylinders are cut off from the fuel supply.
Thus, in response to the TCS operation level determined, any of the coefficient KAGTCS1-5 corresponding thereto is selected at step S302. Then control passes to step S304 in which the selected coefficient is treated as the current coefficient KAGTCS. On the other hand, if the bit of the flag FTC is found to be zero at step S300, control passes to step S306 in which the coefficient is set to be 1.0.
With the arrangement, as illustrated in FIG. 10, the coefficient increases with increasing TCS operation level. As a result, the reference level KLVL becomes higher as the amount of the engine output torque reduction increases. The occurrence of a combustion knock can therefore be detected more precisely so that a knock control can be carried out more appropriately.
In the second embodiment, although the engine output torque is reduced stepwise by the fuel cut in response to the slip ratio, it can alternatively be possible to reduce the torque also stepwise or gradually by adjusting the ignition timing or an air-fuel ratio of the engine as earlier mentioned.
In the first and second embodiments, it should be noted, since the characteristic feature of the present invention resides in a combustion knock detection system per se, the knock control, if a combustion knock is detected in the manner disclosed, can be carried in any appropriate manner.
Further, although the reference level KLVL is enlarged in the first and second embodiment by enlarging the coefficient KAGTCS for the amplification gain, it should be noted that the reference value can be enlarged in various ways such as by immediately multiplying a coefficient to the reference level or the noise level.
Furthermore, although the knock sensor used in the first and second embodiments is the one which detects the vibration generated in the engine, other type of detonation sensors, for example, one for detecting combustion pressure or sound wave and the like can be used.
The present invention has thus been shown and described with reference to the specific embodiments. However, it should be noted that the present invention is in no way limited to the details of the described arrangements, but changes and modifications may be made without departing from the scope of the appended claims.
|
A system for detecting a combustion knock occurred in a combustion chamber of an internal combustion engine. The system includes a sensor for detecting vibration generated in the engine. Sensor output within a range of crankshaft angles during which no combustion occurs is averaged and amplified to determine a reference noise level. Sensor output within another range of crankshaft angles during which combustion occurs is compared with the reference noise level and if the sensor output exceeds the reference noise level, a combustion knock is determined to be present. In the system, a traction control system (TCS) is incorporated in which the engine output torque is reduced when the driven wheel of the vehicle on which the engine is mounted is great. The reference noise level is enlarged when the TCS operates such that the mechanical vibration increased by the sudden change in the torque due to the TCS operation is prevented from being erroneously detected as the combustion knock.
| 5
|
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the priority of Swiss Patent Application No. 01780/09, filed on Nov. 18, 2009, the entirety of which is hereby incorporated by reference.
BACKGROUND
1. Field of Invention
The invention relates to a transport device for conveying printed products, wherein the transport device includes a conveying chain configured for a predetermined section and composed of a number of functional units that can be connected to each other.
2. Related Art
Conveying chains of this type are used for transporting printed products between individual processing stations, such as inserting machines, addressing units, adhesive-application apparatuses or the like. For this, the printed products are generally held in place by grippers mounted on the chain links and, if applicable, are released by these grippers at the processing stations. To ensure a continuous operation, the links of the conveying chain are normally driven so as to circulate continuously along the conveying section. The conveying chain is guided along the conveying section with the aid of suitable guide arrangements or guide rails which can also determine the curves of the conveying section. To ensure mobility along the conveying section, the chain links must be connected articulated, meaning so as to pivot independently around two axes, wherein the conveying section can have a length of 100 m or more. As a result, the installation of the guide rail arrangement and the chain links is correspondingly involved, wherein the articulated connection between the individual chain links must be ensured over the complete length of the conveying chain.
For the conveying chains described in Swiss patent document CH 588 647 A5, the installation of the chain links connected via spherical joints is to be facilitated by embodying the joint sockets and joint members as equatorial spherical segments. The idea of equatorially divided spherical segments is also picked up in Swiss patent documents CH 646 762 A5 and CH 656 683 A5. However, this type of design for articulated connections between individual chain links does not substantially facilitate the installation of the conveying chains on or in the guide rails.
Some degree of simplification is proposed for the installation of conveying chains as disclosed in Swiss patent document CH 593 187, for which the chain links made of plastic are detachably connected with the aid of pivoting axes and hubs that are oriented transverse to their longitudinal direction, wherein additional components are attached, so as to be detachable, to fastening elements of the chain links. However, the installation of the chain links on or in the guide rail arrangements or in the guide rails still presents considerable problems, even with the conveying chains described in this document. Somewhat easier is the installation of conveying chains as disclosed in U.S. Pat. No. 4,638,906 for which the individual chain links can be detached from each other by turning them around an axis extending parallel to the conveying direction wherein, however, the guide rail must be provided for this with corresponding openings.
The installation of a conveying chain as described in European patent document EP 1 832 532 A2 is to be made easier by having the bearing housing rest on two bearing housing parts which bridge a spherical bearing element to form a spherical joint. The idea of dividing the bearing elements into equatorial planes is again taken up in this document.
Finally, it is proposed in European patent document EP 1 557 387 A1 to make available cost-effective conveying chains by attaching to each link of the chain at least two clamps or grippers which respectively grip one printed product.
The above-provided explanations for the known chains used for conveying printed products show that considerable problems are encountered during the installation of said conveying chains along a conveying section which is predetermined by a guide rail arrangement while simultaneously ensuring a sufficient mobility for the conveying chain along a curved conveying section.
SUMMARY
The invention is intended to remedy this problem. It is an object of the invention, as characterized in the claims, to propose a design for a transport device of the aforementioned type which is distinguished by its simplicity and which above all can be produced cost-effectively. It is furthermore an object of the invention to decisively extend the service life of a conveying chain formed with a number of chain links and to minimize the noise developing during the operation.
According to an embodiment of the invention, a transport device for conveying printed products is provided. The transport device includes a conveying chain. The conveying chain includes at least two functional units arranged sequentially along a conveying section and connected to each other by a connecting element. Each functional unit includes a first chain link and a second chain link. The first and second chain links are operatively connected to one another and differing in their respective functions.
According to another embodiment, the conveying chain is composed of at least two functional units, essentially arranged sequentially along the conveying section, that the sequentially arranged functional units form a rigid and/or an articulated connection, that the respective functional unit consists of a first chain link and a second chain link which differ in their function and are operatively connected, that in order to form the conveying chain the functional units are configured congruent or quasi-congruent or the like in their sequence or that the functional units are configured different with respect to functionality, and that the sequentially arranged functional units are provided with means or connecting elements for creating a detachable connection or a conditionally detachable connection caused by traction and/or a non-detachable connection.
The conveying chain includes a number of so-called conveying units and that each conveying unit in turn comprises a first chain link and a second chain link, wherein it is specified at the same time that the individual conveying units are also operatively connected to each other, regardless of the type of connection that is used between the individual elements.
The otherwise required physical mobility of the conveying chain along a curved conveying section can be ensured for conveying chains according to embodiments of the invention by using functional units to form the conveying chain which functional units can either be connected rigid or articulated to each other. The connection options between the links that form the functional unit are discussed in further detail below. During the installation of the conveying chains according to embodiments of the invention, it is possible to produce conveying chain segments comprising a number of joint arrangements and/or conveying chain arrangements ahead of time and to insert these into a guide rail arrangement. Adjacent functional units can then be connected rigidly to form the conveying chain. The installation is thus on the whole made noticeably simpler because the articulated connections, required for ensuring the functional safety of the conveying chain, can already be produced along with the conveying chain at the production location and because only rigid connections between the individual functional units must be formed during the installation at the location of installation.
In view of the different functions to be met by respectively two chain links, for example the drive function and the guide function, it has proven useful if the functional unit created by connecting two chain links consists of a chain link embodied as a first functional link and a different chain link embodied as a second functional link since this allows assigning individual functions to individual chain links which, on the whole, results in a functional improvement and/or an improvement of the operational reliability for the conveying chains according to embodiments of the invention. To form a rigid connection between the individual chain links of a functional unit, it has proven useful if these chain links can engage form-locking in a connecting region, in particular if they can interlock, wherein the form-locking connection can be secured with the aid of a detachable connecting element. A similar or identical connection can also be provided between the functional units.
The connection between the individual chain links, relative to the sequentially adjacent links, can be realized with the aid of hook-shaped projections that extend transverse to the conveying direction and interlink for the form-locking connection. In the process, the connecting region for one of the chain links can overlap the connecting region for the other chain link as seen in conveying direction and thus produce a secure connection. The connecting element in particular can take the form of a screw bolt that extends through a recess provided in one of the chain links and is screwed into a thread provided in the other chain link, wherein the screw bolt advantageously fits with its head, arranged opposite the thread, at least indirectly against a chain link.
During the installation of the conveying chains according to an embodiment of the invention, the individual chain links of a functional unit can therefore initially be positioned by interlocking them in the connecting region and can then be secured in this position with the connecting element. It has turned out that the installation of conveying chains according to an embodiment of the invention can be realized particularly easily if the axis of the screw bolt extends transverse, especially perpendicular, to the conveying direction since this arrangement makes it possible to provide an especially large space for installation options, especially installation openings, in the guide rail arrangements. Slot-shaped openings of this type which extend in conveying direction of the guide rail arrangement are already required in the functional devices used for conveying the printed products in guide rail arrangements, such as grippers and clamps. Starting from the conveying chain, these extend in a direction transverse to the conveying direction and must be freely accessible outside of the guide rails.
In view of this arrangement of the functional devices and considering the desired easy installation, it has proven to be especially useful if, on the side facing away from the thread, the screw bolt for connecting the chain links extends through a connecting device for connecting a functional unit extending transverse to the conveying section, e.g. a gripper, a clamp, or the like. The connecting device as component of the functional device can be fixedly connected thereto. In view of the frequently desired high modularity of systems provided with conveying chains according to embodiments of the invention, it has proven favorable if the connecting device forms an adapter which can be used for connecting the functional device to the conveying chain, wherein different connecting devices or adapters can be used for connecting different functional devices.
As previously addressed in the above, the use of chain links that differ from each other is particularly helpful considering the desired optimization of the individual functions of the conveying chain. In this connection, it has proven useful if the first chain link is provided with a region for connecting the conveying chain to a drive unit and if the second chain link is provided with a guide device for guiding the conveying chain along a guide rail arrangement. As compared to standard drive units, such as the ones disclosed in European patent document EP 0 540 866 A2, which engage in the region of the guide arrangements in the conveying chains and subject the guide elements to increased wear because of the simultaneous drive function, the inventive arrangement results in an improvement in the operational reliability of conveying chains as a result of the aforementioned separation between the conveying function on the one hand and the guide function on the other hand.
In addition, the standard drive unit for conveying chains requires an intervention in the conveying arrangement in the area of the guiding devices, meaning in the area of the guide rails or the guide rail arrangement, and in many cases also requires that the conveying chain is looped around a drive element. With the separation of the connecting region for the conveying device on the one hand and the guiding device on the other hand, the chain drive can be realized completely separate from the guiding function and the conveying function for the printed products. As a result, a further functional optimization is achieved.
In view of providing an especially large area for installing the functional devices to be attached to the conveying chain, it has proven especially useful if the connecting region for the drive unit is arranged on the side of the functional arrangement opposite the bolt head which is used for connecting the functional device, if applicable via a connecting device, so that with functional devices that are suspended below the conveying chain, such as grippers, the drive unit can be arranged above the conveying chain and cooperates with the connecting regions which in this position extends upward and away from the conveying chain.
The connecting region can be realized particularly easily if it takes the shape of a comb, having teeth that extend transverse, in particular approximately perpendicular, to the conveying direction. The chain bolts of a drive chain can then engage in the spaces between the teeth for the purpose of driving the conveying chain. This design also does not require the conveying chain to be looped around a drive wheel. Rather, the conveying chain can also be driven along a straight-line segment of the conveying section. However, it is useful in that case if the conveying chain is supported on the side opposite the conveying device on or in a guide rail arrangement. The guide arrangement of the second chain link in this case is usefully provided with one, preferably two, three or more guide rollers which are positioned so as to rotate relative to the respective roller axes. The desired functional separation between the drive function on the one hand and the guide function on the other hand can be achieved especially effectively if all guide rollers are arranged on the side facing a device for connecting a functional unit, such as a gripper, in the region designed for connecting the drive unit, so as to allow free access to the connecting region outside of the guide rollers.
Even though the guide rollers can be arranged on the second chain link in such a way that they are offset along the conveying direction, it has proven useful in view of the most compact design possible for the conveying chains according to an embodiment of the invention if two guide rollers are arranged so as to rotate relative to a joint first roller axis which extends transverse and especially perpendicular to the conveying section and/or the conveying direction, wherein two additional guide rollers are positioned so as to rotate around a joint second roller axis, relative to a plane that is positioned transverse, especially approximately perpendicular, and is defined by the conveying direction and the first roller axis. To obtain a symmetrical design, the guide rollers can also be arranged on the sides of a cuboid, wherein the roller axes extend along its median lines.
According to an embodiment of the invention and in view of providing a particularly reliable guide function for guide rail arrangements which can comprise curved regions in all spatial directions, it has proven especially useful if the device for guiding the respective chain link comprises at least four guide rollers, wherein respectively two guide rollers are positioned rotating relative to a joint roller axis, and the two roller axes are arranged perpendicular to each other in one plane. For the purpose of a compact design, it has proven especially useful if at least one guide roller is positioned rotating on a guide pin used for the second functional link because the desired guiding function can thus be realized without actual continuous roller axes, wherein the rotating positioning can be ensured with respect to a joint geometric roller axis even if additional functional regions are located between individual regions of the second functional element which are designed for the rotating positioning of the guide rollers.
In the same way as for the traditional conveying chains, the links of the articulated arrangement for conveying chains according to an embodiment of the invention can also pivot around two pivoting axes extending transverse, especially approximately perpendicular, to each other in order to provide the mobility along curved guides which are delimited only by their curvature radius. The chain links of the articulated arrangement can be connected for this with the aid of a spherical joint arrangement comprising a spherical segment and a spherical-shell segment. Within the meaning of an especially compact design for conveying chains according to an embodiment of the invention, it has proven useful if the spherical segment and the spherical-shell segment are attached to an insertion region on one of the chain links and, together with this insertion region, are accommodated in a holding region on the other chain link of the articulated arrangement.
For a secure connection between the chain links of the articulated arrangement, a connecting bolt that extends through the area accommodating the other chain link can extend through the spherical segment and the spherical-shell segment. In that case, the insertion region of the one chain link of the articulated arrangement, which carries the spherical segment and the spherical-shell segment, is initially inserted into the region for accommodating the other chain link during the installation. The connecting bolt is then guided through an opening extending through the spherical segment, the spherical-shell segment and the holding region so as to create a connection between the two chain links for which the spherical segment can be secured with the bolt, relative to the chain links provided with the holding region, while the spherical-shell segment together with the insertion region in the respective chain link can be pivoted around the spherical segment, thereby making it possible to pivot the chain link comprising the insertion region, relative to the chain link with the holding region.
For the purpose of achieving especially high wear resistance for the conveying chains according to an embodiment of the invention, it has proven advantageous if the spherical segment is made of metal while the spherical-shell segment can be composed of a plastic material with low friction coefficient, for example a polyamide or a Teflon-containing plastic. For the purpose of a particularly easy production, it is advantageous if the insertion region is embodied form-locking or material-to-material with the spherical-shell segment, such that the insertion region together with the spherical-shell segment is positioned so as to rotate relative to the spherical segment. The insertion region can be formed, for example, by insert-molding of the spherical-shell segment with a preferably fiber-reinforced plastic. The spherical-shell segment can be composed of pre-fabricated single-part, two-part or multi-part shells which are fitted around the spherical segment, wherein a centering means can be provided if necessary on the frontal surfaces of the partial shells which face each other. For the purpose of guiding the pivoting movement of the chain links, relative to the axis for the bolt connecting the insertion region with the holding region, the insertion region can be embodied as a circular segment of a disk surrounding the bolt axis, wherein the peripheral area of the holding region can also be embodied as a shell segment of a circular disk.
It is particularly easy to produce the conveying chains according to an embodiment of the invention while simultaneously avoiding an excess number of different components and by ensuring a corresponding positioning if one functional unit of the articulated arrangement is embodied as first chain link for the functional arrangement and the other functional unit of the articulated arrangement is embodied as second chain link of the functional arrangement.
With this embodiment of the invention, the individual functional units of the articulated arrangement can be connected securely and reliably while avoiding any influence on the connection between the drive unit and the conveying chain, provided the insertion region comprises a bolt that laterally connects the chain links and preferably also contains a projection that advantageously extends approximately along the conveying direction. The circular disk-shaped insertion region can be arranged in a plane, defined by the conveying direction and the screw-bolt axis, so as to ensure a sufficiently high rigidity in case of stress exerted by the loads attached thereto and normally are positioned below. At least one roller axis can extend through the holding region in that case, wherein the axis for the connecting bolt extends approximately parallel, preferably approximately co-linear, to the second roller axis while the first roller axis is arranged in the plane for the disk-segment shaped insertion region. In that case, the insertion region is arranged between the guide pins for the second functional element on which the guide rollers are mounted so as to rotate, relative to the first roller axis.
A conveying chain can thus be provided with successively positioned articulated arrangements and functional arrangements if respectively one first chain link is arranged between two second chain links. Each second chain link is connected on one side articulated to one of the first chain links and is connected on the other side rigidly to the other one of the first chain links.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the invention will be further understood from the following detailed description of some embodiments with reference to the accompanying drawings, in which:
FIG. 1 A view from the side of a conveying chain according to an embodiment of the invention;
FIG. 2 A view from above of a conveying chain according to an embodiment of the invention;
FIG. 3 A sectional representation of a functional arrangement of a conveying chain according to an embodiment of the invention;
FIG. 4 A perspective representation of an articulated arrangement of a conveying chain according to an embodiment of the invention;
FIG. 5 A first sectional representation of an articulated arrangement of a conveying chain according to an embodiment of the invention;
FIG. 6 A second sectional representation of an articulated arrangement of a conveying chain according to an embodiment of the invention;
FIG. 7 A representation illustrating the installation of conveying chains according to an embodiment of the invention;
FIG. 8 A view from the side of a first functional element of the conveying chains according to an embodiment of the invention;
FIG. 9 A first sectional representation of the first functional element shown in FIGS. 4 and 8 ;
FIG. 10 A second sectional representation of the first functional element shown in FIGS. 4 and 8 ;
FIG. 11 A view from the side which shows the connection of a drive unit to a conveying chain according to an embodiment of the invention;
FIG. 12 A representation illustrating the installation of conveying chains according to another embodiment of the invention;
FIG. 13 A representation illustrating the installation of conveying chains according to yet another embodiment of the invention; and
FIG. 14 A representation illustrating the installation of conveying chains according to still another embodiment of the invention.
DETAILED DESCRIPTION
According to an embodiment, a conveying chain shown in FIG. 1 comprises functional units in the form of first chain links 100 and second chain links 200 . Each of the first chain links 100 is provided with a comb-shaped connecting region 110 for connecting the conveying chain to a drive chain 530 (see FIG. 11 ). As shown in the embodiment depicted in FIGS. 1 and 2 , each of the second chain links 200 is provided with a total of four guide rollers 202 , 204 , 206 , 208 , wherein the guide rollers 206 and 208 are positioned rotating, relative to a first joint roller axis, and the guide rollers 202 , 204 are positioned rotating, relative to a second joint roller axis. The first and the second roller axes extend perpendicular to each other and are arranged in one plane. Each of the first chain links 100 is arranged between two second chain links 200 . To form a functional arrangement, each of the first chain links 100 is thus connected rigidly on one side with one of the second chain links 200 and is connected on the other side with the other one of the second chain links 200 , so as to form an articulated arrangement.
FIG. 3 illustrates the rigid connection between first chain links 100 and second chain links 200 which results in creating the functional arrangement. In order to connect the first chain links 100 to the second chain links 200 , a screw bolt 300 is thus inserted and extends through a bore in a connecting region 250 of the second chain link 200 and is screwed into a connecting region 150 of the first chain link 100 . A blind hole 152 (see FIGS. 5 and 9 ) is thus formed in the first chain link 100 with therein inserted thread insert 310 into which the bolt 300 is screwed. According to FIG. 5 , the blind hole 152 is arranged below the comb-shaped connecting region 110 . Following the connecting of the first chain link 100 and the second chain link 200 , all guide rollers 202 , 204 , 206 , 208 are arranged on the side of the comb-shaped connecting region 110 that faces the bolt head 302 of the screw bolt 300 , so that the comb-shaped connecting region 110 outside of the guide rollers 202 , 204 , 206 , 208 can be freely accessed. The bolt head 302 fits flush against the side of the second chain link 200 that is facing away from the comb-shaped connecting region 110 , with a connecting device 310 disposed in-between. The connecting device 310 is used to attach functional units such as gripper elements or clamping elements to the conveying chain.
FIG. 4 shows that the connecting region 250 of the second chain link 200 is provided with a projection 256 and a grooved recess 252 into which a convex area 254 of the projection 256 extends. Complementary thereto, the connecting region 150 of the first chain link 100 is embodied with a projection 154 that engages in the grooved recess 252 and is provided with a recess 156 for accommodating the projection 256 , wherein the projection 154 is furthermore provided with a concave area 155 (see FIG. 5 ) for accommodating the convex area 254 , so that by inserting the connecting region 150 of the first chain link 100 into the connecting region 250 of the second chain link 200 , a form-fitting connection is created between the first chain link 100 and the second chain link 200 which can be locked in place with the aid of the screw bolt 300 (see FIG. 3 ) that extends through the projection 256 and is inserted into the blind hole 152 (see FIG. 5 ) formed between the recess 156 and the comb-shaped connecting region 110 of the first chain link 100 . To further secure the position of the form-locking connection between the first connecting region 150 and the second connecting region 250 , the projection 256 is also provided with a hook-shaped engagement region 258 (see FIG. 4 ) which engages in a further depression 157 in the recess 156 (see FIG. 5 ).
According to FIG. 3 , the comb-shaped connecting region 110 is embodied in the manner of a comb having teeth that extend approximately parallel to the axis of the screw bolt 300 , wherein an intermediate space exists between the teeth of the comb in which the chain bolts of the drive chain 530 engage (see FIG. 11 ). The guide rollers 202 , 204 , 206 , 208 are positioned rotating on guide pins 212 , 214 , 216 , 218 , so that between the guide pins 212 , 214 , 216 , 218 a structural space is still available for producing an articulated connection between first chain links 100 and second chain links 200 . The articulated arrangement produced by connecting the first chain links 100 and the second chain links 200 is explained with the aid of FIGS. 3-6 .
According to FIGS. 4 and 5 , the first chain link 100 is provided in conveying direction with an insertion region 120 that extends transverse to the bolt axis and is accommodated within a holding region 220 that is formed between the guide pins 212 , 214 , 216 , 218 of the second chain link 200 . The insertion region 120 takes the shape of a circular disk segment while the holding region 220 is embodied in the shape of a shell-type circular disk segment, so that a guide is formed by the peripheral areas of the insertion region 120 and the holding region 220 for a pivoting movement of the first functional element 100 , relative to the second functional element 200 , around a pivoting axis formed by the second roller axis.
According to FIG. 6 , the articulated connection between the first chain link 100 and the second chain link 200 contains a spherical segment 124 , accommodated in the insertion region 120 , wherein a sliding element 122 in the shape of a spherical-shell segment which is made of a plastic and has a low frictional coefficient is arranged between the spherical segment 124 and the outside area of the insertion region 120 . The spherical segment 124 and the spherical-shell segment 122 extend through the insertion region 120 . With the aid of the spherical-shell segment 122 , the insertion region 120 which holds the spherical segment 124 is positioned such that it can rotate on the spherical segment 124 (see FIG. 10 ). Thus, following the insertion of the insertion region 120 into the holding region 220 , the first chain link 100 with the insertion region 120 is consequently positioned rotating, relative to the axis for the connecting bolt 126 and an axis 128 that extends perpendicular thereto and parallel to the screw bolt 300 , wherein the pivoting movement relative to the pivoting axis 128 is fixed by the width of the holding region 220 in the direction that is determined by the axis of the bolt 126 . If necessary, this width can be increased.
FIG. 7 shows an installed conveying chain according to an embodiment of the invention, wherein this Figure is explained in further detail below.
In FIG. 8 , the first chain link 100 is shown in further detail including the comb-shaped connecting region 110 and the insertion region 120 . According to FIG. 10 , the insertion region 120 on the first chain link 100 is embodied by partially enveloping the spherical segment 124 with a plastic material having low friction in order to form a spherical-shell segment 122 , wherein the spherical segment 124 formed in this way can be produced by surrounding it with an injection-molded coat of plastic, especially a fiber-reinforced plastic, to form the insertion region 120 . The spherical-shell segment 122 is embodied as one piece, but can also consist of two parts or several parts. During the injection-molding process, the connecting region 150 and the comb-shaped connecting region 110 can furthermore be formed at the same time, wherein it is also conceivable during the injection-molding process to insert the threaded insert 310 into the blind hole 152 (see FIG. 9 ). According to the embodiment depicted in FIG. 7 , the conveying chains can be installed by first pre-assembling articulated arrangements or functional units consisting of first chain links (functional elements) 100 and second chain links (functional elements) 200 , which are then fitted together in the connecting regions 150 and/or 250 and are subsequently locked into place with the aid of the screw bolts 300 . The depicted sequence includes three sequentially arranged functional units. The first and the second units (from left to right) are the same and define a “congruent” sequence. The third unit includes a difference in that this unit does not include a connecting device 310 . Thus, the sequence including the third unit can be called “quasi-congruent.”
According to an embodiment of the invention depicted in FIG. 11 , the conveying chains can convey along a section formed by a guide rail arrangement 600 , wherein the conveying chain is accommodated inside the guide rail 600 and is moved with the aid of guide rollers 202 , 204 , 206 , 208 along corresponding running surfaces of the guide rail 600 . The comb-shaped connecting regions 110 are located in a drive space 610 for the guide rails 600 and engage in drive sections of the guide rail arrangement 600 in a drive chain 530 of a drive unit 500 which moves around two chain wheels 510 and 520 . To connect the drive unit 500 , it is only necessary to produce a recess in a peripheral area of the drive space 610 through which the drive chain 530 can move into the comb-shaped connecting regions 110 .
According to the embodiment depicted in FIG. 12 , the conveying chains can be installed by first pre-assembling articulated arrangements or functional units consisting of first chain links 100 and second chain links 200 , which are then fitted together and are subsequently locked into place with the aid of the screw bolts. The depicted sequence includes three sequentially arranged identical functional units, each including a connecting device 310 , and defining a congruent sequence.
According to the embodiment depicted in FIG. 13 , the conveying chains can be installed by first pre-assembling articulated arrangements or functional units consisting of first chain links 100 and second chain links 200 or first chain links 100 a and second chain links 200 , which are then fitted together and are subsequently locked into place with the aid of the screw bolts. The depicted sequence includes three sequentially arranged functional units. The first and third units (from left to right) are the same. The second unit includes a difference in that this unit does not include, for example, a comb-shaped connecting region 110 on the first chain link 100 a or a connecting device 310 attached to second chain link 200 .
The invention is not restricted to the embodiment explained with the aid of the drawings. Rather, it can conceivably also be used for conveying chains with differently designed guide rail arrangements, having three or fewer guide rollers, guide pins or the like. The connecting regions of the conveying chain can furthermore be embodied differently, wherein a cardanic connection between the individual chain links is also conceivable when forming articulated arrangements.
A number of options are possible within the scope of the invention. In particular, functional units that consist of respectively a first and a second operatively connected chain links 100 , 200 , as previously explained, can be configured with a congruent (see FIG. 12 ) or quasi-congruent (see FIG. 7 ) sequence or the like (see FIG. 13 ), or can also have different functionality (see FIG. 13 ). Of course, the different functions of the two chain links as well as the connecting options relative to each other are maintained. It is also possible that a second chain link does not always immediately follow a first chain link, for example, but that two or more second chain links follow a first chain link, or vice versa, namely that two or more first chain links are connected successively. The sequentially arranged functional units in that case are provided with means or connecting elements for a detachable connection or a conditionally detachable connection due to traction or a non-detachable connection. It means on the one hand that the geometric and functional embodiment of the individual guide units does not have to be uniform over the complete conveying chain and that variations in-between are possible which depend on the operation. On the other hand, it is emphasized that the functional units used to form the conveying chain can also be connected differently, relative to each other, wherein a detachable connection such as a screw connection will for the most part be selected in that case. However, if necessary a frictional connection which functions in the manner of a detachable connection can also be provided. Finally, there is the option of creating a non-detachable connection between the individual functional units, e.g. a welded connection between a second chain link 200 b and a first chain link 100 b of consecutive pre-assembled functional units (see FIG. 14 ).
|
A transport device for conveying printed products. The transport device includes a conveying chain. The conveying chain includes at least two functional units arranged sequentially along a conveying section and connected to each other by a connecting element. Each functional unit includes a first chain link and a second chain link. The first and second chain links are operatively connected to one another and differing in their respective functions.
| 1
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to gas lift apparatus and more particularly to side pocket mandrels for use in gas lift wells.
2. Description of the Prior Art
Side pocket mandrels with orienting means therein for orienting a kickover tool used in installing well flow control devices in or removing them from their offset receptacles have been used for many years. Side pocket mandrels and kickover tools therefor have been supplied by a number of suppliers in the industry. Kickover tools from one supplier may not work well in the side pocket mandrels of another supplier even though such kickover tool may have been intended for use in such side pocket mandrel. It has been desirable to provide a side pocket mandrel which would be compatible with virtually any kickover tool designed for use with such mandrel and to minimize difficulties arising from such mismatching.
The orienting means in side pocket mandrels have been in the form of a sleeve surrounding the bore through the side pocket mandrel, this sleeve being provided with a pair of symmetrical guide surfaces generally helical in shape leading from a point at the lower end of the sleeve upwardly to the lower end of a longitudinal orienting slot. In some cases where the sleeve provides orientation only, this slot may pass completely through the sleeve. In other mandrels the slot may be provided with a shoulder, and in some cases this shoulder completely blocks the slot. Such shoulder at the upper end of the slot is utilized in activating a kickover tool after it has first been oriented.
Kickover tools of the orienting type are provided with an orienting key sufficiently narrow to enter the orienting slot in the orienting sleeve and have an abrupt upwardly facing shoulder thereon. When this abrupt shoulder engages the orienting sleeve, it will follow one of the guide surfaces causing the kickover tool to rotate about its longitudinal axis until the key becomes aligned with and enters the slot, thus orienting the kickover tool with respect to the side pocket mandrel, that is, positioning the kickover tool for installing a device in the offset receptacle of the side pocket mandrel. In some cases, as where wireline equipment is used, the same abrupt shoulder of the orienting key also engages the shoulder in the slot, and further movement of the kickover tool causes it to be activated such that a portion thereof is shifted laterally into alignment with the offset receptacle of the side pocket mandrel.
Kickover tools are commonly run into wells and removed therefrom by conventional wireline equipment or by conventional pumpdown operations. In the latter, the kickover tool and a string of pumpdown tools including piston units are moved by fluid pressure into and out of the well by circulation of fluids through the well. Whether the kickover tool is run by wireline or by pumpdown methods, it is sometimes difficult to control the velocity of the kickover tool with respect to the side pocket mandrel. Thus, it often occurs that the kickover tool moves through the side pocket mandrel at excessive velocities. This may be due to the drag of the tools in the well tubing during pumpdown operations and also due to the fluid bypass through the kickover tool. These may cause the tools to lodge momentarily in tight places in the tubing and then move quickly until stabilization occurs and normal velocity is restored. Similarly, in wireline operations (the wireline being elastic), such a condition can occur. This condition can be further aggravated where the wireline reel is mounted on a floating vessel which tosses about on the water's surface relative to the well which is stationary with the earth. When the kickover tool moves too fast relative to the side pocket mandrel, its orienting key may fail to enter the slot of the orienting sleeve. One particular type or orienting key has failed frequently and caused considerable difficulty. When this type of key engages one of the guide surfaces on an orienting sleeve while the kickover tool is moving rapidly with relation thereto, considerable rotational force is applied to the kickover tool. In such case, the orienting key may strike the juncture of the opposite guide surface and the opposite wall of the slot in such manner that it causes the orienting key to retract momentarily and pass through the sleeve without ever orienting the kickover tool.
The present invention overcomes such difficulty in a manner which will be hereinafter explained.
A search of the prior art was made, and the following U.S. patents were located, each of which illustrates an orienting sleeve in a side pocket mandrel.
______________________________________2,942,671 3,807,498 4,034,8062,948,341 3,827,489 4,051,8953,353,607 3,827,490 4,066,1283,581,818 3,837,398 4,103,7403,610,336 3,874,445 4,106,5633,727,683 3,876,001 4,106,5643,732,928 3,889,748 4,135,5763,741,299 3,891,032 4,146,0913,741,303 3,965,979 4,197,9093,752,231 4,002,203 4,239,0823,788,397 4,031,954 4,271,9023,796,259 4,033,409 4,294,313______________________________________
Included in the above list are three patents which are considered exemplary of the types of side pocket mandrel orienting sleeves of which the present invention is an improvement. The list also includes a fourth patent which illustrates and describes a kickover tool having an orienting key of the type which has been associated with the failures discussed hereinabove.
U.S. Pat. No. 2,942,671 which issued to Harry B. Schramm on June 28, 1960 discloses a side pocket mandrel with an orienting sleeve therein, the orienting sleeve having a pair of guide surfaces which lead to a longitudinal orienting slot which passes completely through the sleeve.
U.S. Pat. No. 2,948,341 which issued to John V. Fredd on Aug. 9, 1960 discloses a side pocket mandrel having an orienting sleeve therein which is provided with guide surfaces leading to a longitudinal orienting slot which passes completely through the sleeve, but the sleeve is further provided with shoulder means located in the slot.
U.S. Pat. No. 3,827,490 which issued to Howard H. Moore, Jr. and Harold E. McGowan, Jr. on Aug. 6, 1974 discloses a side pocket mandrel having an orienting sleeve therein having a pair of guide surfaces leading to an orienting slot and a trip shoulder at the end of the slot which completely blocks the slot. These three patents are typical of the types of orienting sleeves which are disclosed in the other patents listed above.
U.S. Pat. No. 3,876,001 which issued to William B. Goode on Apr. 8, 1975 illustrates and describes a kickover tool for use in side pocket mandrels which are equipped with orienting sleeves such as that just mentioned with respect to U.S. Pat. No. 3,827,490. This kickover tool is equipped with an orienting key having a portion thereof protruding from a window and presenting cam surfaces which would tend to cam the key inwardly toward retracted position when meeting with obstructions in the well tubing. This key has an upwardly opening radial slot at its upper end and has a filler piece pivotally mounted in the slot. This filler piece is shear-pinned in place to releasably hold it in the position shown, in which position the filler piece presents an abrupt upwardly facing shoulder to engage the guide surfaces and trip shoulder of an orienting sleeve. Upon shearing the shear pin, the filler piece becomes inoperative, and the key will thereafter pass shoulders or obstructions with readiness because of the key's cam surfaces mentioned earlier camming the key toward retracted position upon encountering obstructions in the well tubing.
There was not found in the prior art patents a side pocket mandrel having a longitudinal orientation slot and a pair of guide surfaces therebelow directed upwardly toward the lower end of the slot but intersecting the slot at different levels which are spaced apart longitudinally. Neither was there found a side pocket mandrel having an orienting sleeve with a longitudinal orientation slot therein and a single guide surface therebelow directed upwardly toward the lower end of the slot from a point at the lower end of the orienting sleeve via a helical path and making substantially a full revolution before intersecting the slot.
The present invention overcomes the problems and shortcomings discussed hereinabove by providing side pocket mandrels having orienting sleeves therein with guide surfaces of a novel form which eliminate malfunctioning as described above and thus saves much time and money.
SUMMARY OF THE INVENTION
The present invention is directed to side pocket mandrels having orienting means therein comprising an orienting sleeve having an orienting slot and a pair of guide surfaces below the slot and directed upwardly toward the slot, these two guide surfaces having their upper ends spaced apart longitudinally with respect to the longitudinal axis of the orienting sleeve. In one aspect of the invention, the orienting sleeve has but a single guide surface.
It is therefore one object of this invention to provide a side pocket mandrel having an orienting sleeve therein, the sleeve having an orienting slot and a guide surface below the slot leading upwardly to the bottom of the slot for orienting a kickover tool in the mandrel with respect to its offset receptacle bore.
Another object of this invention is to provide such a side pocket mandrel with an orienting sleeve therein having an orienting slot and a pair of guide surfaces below the slot directed upwardly toward the bottom of the slot, the two guide surfaces having their upward ends spaced apart longitudinally.
Another object is to provide a side pocket mandrel having an orienting sleeve with a slot therein and a pair of guide surfaces directed upwardly toward the bottom of the slot, these two guide surfaces being helical in form and having unequal helix angles.
Another object of the invention is to provide a side pocket mandrel with such an orienting sleeve wherein the two guide surfaces extend upwardly from a point which is angularly displaced from the location of the orienting slot by approximately 90 degrees.
Another object of this invention is to provide side pocket mandrels of the character just described wherein there is provided a stop shoulder in the orienting slot of the orienting sleeve for activating a kickover tool.
Another object is to provide side pocket mandrels of the character described wherein the stop shoulder completely blocks the slot in the orienting sleeve.
Another object of this invention is to provide a side pocket mandrel of the character described having an orienting sleeve located above the belly in the side pocket mandrel.
Another object of this invention is to provide side pocket mandrels of the character described having an orienting sleeve positioned below the upper end of the offset receptacle.
Other objects and advantages will become apparent from reading the description which follows and from studying the accompanying drawings wherein:
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1A and 1B taken together constitute a longitudinal sectional view of a side pocket mandrel constructed in accordance with the present invention and showing an orienting sleeve near its upper end.
FIG. 2 is a side elevational view of an orienting sleeve constructed in accordance with this invention.
FIG. 3 is a fragmentary side elevational view showing a portion of a kickover tool having an orienting key usable with the present invention.
FIGS. 4A and 4B taken together constitute a longitudinal sectional view of a side pocket mandrel constructed in accordance with this invention and having an orienting sleeve therein positioned near its lower end.
FIG. 5 is a side elevational view of the orienting sleeve which forms a part of the mandrel of FIG. 4B.
FIG. 6 is a side elevational view of a modified form of orienting sleeve.
FIG.7 is a lower end view of the orienting sleeve of FIG. 6.
FIG. 8 is a side elevational view of a further modified form of orienting sleeve.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1A, 1B and 2, it will be seen that the side pocket mandrel is indicated generally by the numeral 10. This mandrel for illustration purposes is constructed generally according to the application of Higgins and Merritt, filed May 12, 1980, Ser. No. 148,928, now U.S. Pat. No. 4,333,527. It is thus shown provided with a welded body 11 having a full-opening bore extending therethrough from end to end and an offset receptacle bore 13 extending alongside the main bore 12 and with means at its upper and lower ends as at 14 and 15 for attachment to a string of well tubing. Lateral flow ports 16 communicate the receptacle bore 13 with the exterior of the mandrel in the well-known manner. Near its upper end, the mandrel is provided with an orienting sleeve 20 which is welded in place as at 21, and this sleeve has a bore 22 which surrounds the main bore 12 through the mandrel. The orienting sleeve 20 is provided with a longitudinal orienting slot 24 having a downwardly facing shoulder 25 at the upper end thereof which may or may not completely block the slot. Sleeve 20 is further provided with a pair of downwardly facing guide surfaces 26 which are directed upwardly toward the lower end of the slot 24, and these guide surfaces are engageable by an orieting key of a kickover tool (not shown). The guide key upon engaging one of the guide surfaces will follow it causing the kickover tool to rotate abouts its longitudinal axis until its orienting key becomes aligned with and enters the orienting slot. When the orienting key is in the orienting slot, the kickover tool is properly oriented in the side pocket mandrel with respect to the receptacle bore 13.
In the past, the two guide surfaces on orienting sleeves have been symmetrical, that is, they have been equal in length, and if helical, have had equal helix angles. In each case, their upper ends have intersected the slot on a common level. Such orienting sleeves worked well with most kickover tools, however, when kickover tools having a certain type of key were used, it was often necessary to make several trips through the side pocket mandrel before orientation of the kickover tool was achieved. Such a kickover tool is partially illustrated in FIG. 3, which see. In FIG. 3, the kickover tool is generally indicated by the numeral 30, and the orienting key is indicated by the numeral 32. The orienting key 32 is bifurcated at its upper end, being provided with an upwardly opening slot 33 in which is disposed a filler piece 34 releasably held in the position shown by a shear pin 35. The orienting key is beveled at its lower end 36 for guiding the key past obstructions as the kickover tool is lowered in the well and is similarly beveled at its upper end as at 37 for guiding the key past obstructions during upward travel of the kickover tool in the well. When the filler piece 34 is in the pinned position shown, its upper end 38 provides an abrupt upwardly facing shoulder on the key which will engage one or the other of the guide surfaces 26 on the sleeve 20 and will follow the guide surface thus causing the kickover tool to operate about its longitudinal axis until the key becomes aligned with the orienting slot 24 and moves upwardly therein.
When the orienting key 32 reaches the upper end of the slot, its filler piece 34 engages the shoulder 25, the filler piece 34 being held in operating position by the shear pin 35. Thus, upward movement of the orienting key 32 is arrested, and further upward movement of the kickover tool will cause relative longitudinal movement between the orienting key and the kickover tool and cause the kickover tool to be activated. With the orienting key in the orienting slot, the kickover tool is correctly oriented with respect to the offset receptacle bore 13, and the kickover tool can be operated to install a device therein or remove a device therefrom. Afterwards, it is necessary to withdraw the kickover tool from the side pocket mandrel. For this operation the kickover tool is lifted again until the filler piece 34 engages the downwardly facing shoulder 25 in the orienting sleeve and sufficient force applied thereto to cause pin 35 to shear allowing the filler piece 34 to rotate about a pivot pin (not shown) to its inoperative position within the key 32. With the filler piece 34 out of the way, the beveled surface 37 at the upper end of the orienting key 32 becomes effective to guide the orienting key past any downwardly facing obstructions such as the downwardly facing shoulder 25 at the upper end of the slot in the orienting sleeve 20, and the kickover tool may thus be withdrawn from the well without difficulty. If the guide surfaces on an orienting sleeve have their upper ends terminate at a common level, as is the case with the prior art devices, and the orienting key of the kickover tool engages one of them at considerable speed, the sudden cam action of the key and guide surface will impart considerable rotational force to the kickover tool and rotate it about its longitudinal axis with considerable angular velocity. This may cause cam surface 37 on the orienting key to strike the far side of the slot at about the juncture of the slot with the opposite guide surface and cause the key to be cammed inwardly allowing it to enter the bore of the sleeve and thus pass through the sleeve without orienting the kickover tool and without the filler piece 34 ever contacting the downwardly facing shoulder at the upper end of the slot. Such difficulty happens with considerable frequency, and in some cases it is very difficult to achieve proper orientation and activation of the kickover tool at all.
It will be noticed in the FIG. 2 that the orienting sleeve 20 of this invention has a bore 22 and is provided with a longitudinally directed orientation slot 24. Near the upper end of the sleeve a downwardly facing shoulder 25 is located in the slot. The shoulder 25 may completely block the slot as shown, or if desired, a narrow slot similar to slot 24a can extend from the shoulder to the upper end of the sleeve as shown in dotted lines. A pair of guide surfaces 26a and 26b are formed on the lower end of the sleeve, and both are directed upwardly toward the bottom of the slot 24.
It will be noticed that the guide surface 26a is longer than the guide surface 26b. It may be preferable for these guide surfaces to be helical and to have different helix angles. Guide surface 26a intersects the slot at the higher position than does the guide surface 26b so that the two places of intersection, 26c and 26d, are spaced apart longitudinally relative to the longitudinal axis of the orienting sleeve. This displacement in most cases will be somewhere near two inches for common sizes of side pocket mandrels.
When a kickover tool such as the kickover tool 30 having a key such as the orienting key 32 thereon approaches the orienting sleeve 20, as when the kickover tool would be lifted through the side pocket mandrel 10, the top end 38 of the filler piece 34 of the key will, in all likelihood, engage one of the guide surfaces 26a, and the kickover tool will be rotated in a counterclockwise direction as seen from the top of the sleeve until the key 32 enters the slot 24. When the kickover tool is lifted further, the filler piece 34 engages the downwardly facing shoulder 25 at the top of the slot 24, the key 32 is stopped, and further movement of the kickover tool may be utilized to bring about relative longitudinal movement between the key and the kickover tool in order to activate the kickover tool in the well-known manner. When the kickover tool is passing through the orienting sleeve 20 at considerable rate of speed and the filler piece 34 of the key engages the guide surface 26a, rapid rotation to the kickover tool occurs, and the momentum causes the kickover tool to tend to rotate past the slot. It will clearly be seen that in such case the key will strike the right-hand wall 24b of the slot, and this rotation of the tool will be stopped allowing the key to then enter the slot. Since the filler piece at this time would be above the point 26d at which the right-hand wall of the slot 24b is intersected by the right-hand guide surface 26b,there is no chance that the key 32 will be cammed inwardly and cause the key to fail to engage the shoulder 25 at the top of the slot.
In similar but different manner, when the kickover tool is lifted at considerable velocity through the side pocket mandrel and the filler piece 34 of the key 32 engages the guide surface 26b of the orienting sleeve, the kickover tool will be rotated rapidly clockwise. When the key reaches the upper end of the guide surface 26b, the momentum will cause the kickover tool to tend to rotate past the slot, but in any event the filler piece 34 of the key 32 should engage the guide surface 26a on the left-hand side of the orienting sleeve as seen in FIG. 2, and the guide surface 26a should then rotate the kickover tool back in the other direction. This time, should the momentum of the kickover tool cause the same to rotate with any considerable force, the side of the key would then strike the right-hand wall surface 24b of the slot above the point 26d as before, and further lifting of the kickover tool would cause the key to move upwardly in the slot. It will be noticed that in this case there has been no tendency for the beveled surface 37 at the upper end of the key to strike the point 26c at which the guide surface 26a intersects the left-hand wall 24c of the slot 24. Thus, the tool should be properly oriented, and there should be little chance that a malfunction in this respect would occur.
Therefore, it has been shown that when a kickover tool such as the kickover tool 30 of FIG. 3 having an orienting key 32 with a filler piece 34 mounted therein is moved upwardly, and the key engages one of the guide surfaces 26a or 26b of the orienting sleeve, even though the kickover tool is moving at considerable velocity, the key will still enter the slot 24, and the filler piece 34 at the upper end thereof will engage the downwardly facing shoulder 25 at the top of the slot. Laboratory tests have shown that in situations where it was difficult to achieve proper orientation and activation of the kickover tool in the mandrel, replacement of the conventional orienting sleeve having conventional guide surfaces with an orienting sleeve having novel guide surfaces such as shown in FIG. 2 has solved the problem. After changing the conventional sleeve for the sleeve of this invention, it was very difficult to pull the kickover tool therethrough without achieving proper orientation.
Referring now to FIGS. 4A, 4B and 5, it will be seen that a side pocket mandrel of modified form is provided. Whereas the mandrel 10 of FIGS. 1A and 1B had its orienting sleeve near the top and thus was for use with kickover tools lowered into the well on a wireline, the mandrel 110 of FIGS. 4A, 4B and 5 has its orienting sleeve near the bottom and is intended for use in pumpdown wells where the kickover tool is moved into and out of the well by circulation of fluids through the well. Pumpdown kickover tools are articulated for passage through flow lines having bends therein as sharp as 60-inch radius, and it so happens that it is more practical to place the orienting key at the lower end of the kickover tool and the orienting sleeve near the lower end of the side pocket mandrel.
Mandrel 110 is seen to comprise a body 111 having a full-opening passage 112 extending therethrough from end to end and having a receptacle bore 113 offset from and extending alongside the main full-open bore 112. Connection means are provided at the upper and lower ends of the mandrel as at 114 and 115 for attachment to a string of well tubing to become a part thereof. Lateral ports such as ports 116 are provided in the wall of the body at the receptacle bore 113 to communicate the bore 113 with the exterior of the mandrel. An orienting sleeve 120 is welded as at 121 into the lower portion of the mandrel as seen in the drawing so that it surrounds the main passage 112. The orienting sleeve 120 is provided with a longitudinally directed orientation slot 124, and this slot may pass completely through the sleeve or may terminate with a cam shoulder such as cam shoulder 152 which is inclined inwardly and upwardly as shown in FIG. 4B. Although the upper end of the pumpdown kickover tool key will not be beveled at its upper end like the key 32, the cam shoulder 125 will cam this key inwardly and will allow the key to pass through the orienting sleeve in the well-known manner. Below the slot 124, the orienting sleeve is provided with guide surfaces 126a and 126b which are not unlike guide surfaces 26a and 26b of sleeve 20 previously described and are directed upwardly from the lower end of the sleeve toward the lower end of the slot. Either of the guide surfaces 126a or 126b is of course engageable by the orienting key and will impart thereto a cam action resulting in rotational movement to the kickover tool to cause the kickover tool to rotate about its longitudinal axis as it is moved through the mandrel in order to bring the orienting key into alignment with the orienting slot. When the orienting key is in the orienting slot, the kickover tool is positioned in the side pocket mandrel so that it is properly aligned with respect to the offset receptacle bore 113. A pumpdown type kickover tool as presently known is not activated by the orienting key striking a shoulder at the upper end of the slot. Instead the kickover tool (not shown) is provided with separate releasable locating means at its upper end which engages a downwardly facing shoulder such as shoulder 140 near the upper end of the side pocket mandrel. This type of kickover tool is illustrated and described in U.S. Pat. No. 3,837,398 which issued Sept. 24, 1974 to John H. Yonker.
It will be noticed that the orienting sleeve 120 of the mandrel 110 is provided with one or more ports 142 through the wall thereof which communicate the interior of the sleeve with the exterior of the mandrel through the lower end of the receptacle bore 113 and the lateral ports 116.
It will be seen in FIG. 5 that the guide surfaces 126a and 126b of sleeve 120 are related to the orienting slot 124 in exactly the same way and perform exactly the same functions as the corresponding guide surfaces 26a and 26b of the orienting sleeve 20 shown in FIG. 2 and before explained. These guide surfaces 126a and 126b intersect the slot 124 at points spaced apart longitudinally and cooperate with the orienting key of a kickover tool in the side pocket mandrel with much greater reliability even though the kickover tool be moved through the mandrel at relatively high velocity. After the pumpdown kickover tool has been oriented and activated and has done kits work, the kickover tool is lifted with respect to the side pocket mandrel. This causes it locating means at its upper end to again engage the downwardly facing shoulder 140 near the upper end of the side pocket mandrel. A greater force is now applied thereto than was applied earlier, causing this mechanism to release and permitting the kickover tool then to be lifted out of the mandrel and withdrawn from the well.
Both of the orienting sleeves thus far discussed have been provided with a pair of guide surfaces which have been unequal in length and having their upper ends intersect the orienting slot at different levels, that is, at levels that are displaced longitudinally from one another with respect to the longitudinal axis of the sleeve and both of the guide surfaces have come together at their lower ends to form a point. As was mentioned, the two guide surfaces are of unequal length and preferably different helix angles. The two guide surfaces, however, could be of different lengths and yet have equal helix angles in which case the point at the lower end of the sleeve would be displaced angularly with respect to the slot. This, however, may not be as desirable as having unequal helix angles as the sleeves in FIGS. 2 and 5 appear to have, but if it is desired to provide a point which is displaced angularly from the slot by something other than 180 degrees, this can be done, and such a sleeve is shown in FIGS. 6 and 7.
In FIGS. 6 and 7 orienting sleeve 220 is seen to have an orienting slot 224 and a trip shoulder at the upper end of the slot. A pair of guide surfaces 226a and 226b are directed upwardly towards the bottom of the slot from a point 227. The point 227 is shown in FIG. 7 to be angularly displaced from the slot 224 by an angle which is shown for illustration purposes to be approximately 90 degrees. The point 227 could as well be displaced some other amount, but in most cases and for practical reasons, the point would be preferred to be either 180 degrees or 90 degrees approximately from the slot.
The orienting sleeve 220 is shown formed with the guide surface 226b having a considerably greater lead than the lead of guide surface 226a.
It is possible to provide an orienting sleeve having only a single guide surface, and such sleeve is illustrated in FIG. 8. Here the guide sleeve 320 has an orientation slot 324 and a trip shoulder 325 at the upper end of the slot. The sleeve has a single guide surface 326 below the slot but directed upwardly toward the lower end of the slot. In this case, the guide surface makes almost a full revolution, and of course the shape of the guide surface is shown to be helical, this being the most practical form.
An orienting sleeve such as the sleeve 320 shown in FIG. 8 will perform quite commendably, but it may not be the most practical in design. It will be noticed that the lower end of the orienting sleeve 320 terminates with a rather sharp point, and this point may be more readily damaged since impacting a kickover tool against it may cause upsetting of the metal. It will be noticed, too, that if such a sleeve is formed with a helical guide surface such as guide surface 326, the distance from the top of the slot to the bottom end of the sleeve is twice what it would be with a conventional type orienting sleeve having two symmetrical guide surfaces. Thus, the sleeve is longer than it ideally needs to be, and since most mandrels are designed so that they are about short as can be and still be practical, such a sleeve as orienting sleeve 320 just may be simply too long, and a sleeve such as that shown in FIG. 2 or in FIG. 6 may be preferred by most operators.
Thus it has been shown that the side pocket mandrels and orienting sleeves illustrated and described herein fulfill all of the objects of the invention set forth at the beginning of this application.
The foregoing description and drawings of the invention are explanatory and illustrative thereof, and various changes in sizes, shapes, materials and arrangement of parts, as well as certain details of the illustrated construction, may be made within the scope of the appended claims without departing from the true spirit of the invention.
|
A side pocket mandrel having an orienting sleeve therein with improved guide surfaces for more reliably orienting a kickover tool with respect to the mandrel preparatory to installing a flow control device in or removing such a device from the mandrel's offset receptacle bore.
| 4
|
This is a divisional application of application Ser. No. 08/058,768, (U.S. Pat. No. 5,423,984), filed Apr. 13, 1993 entitled "AN IMPROVED FLUID FILTER".
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a filter system designed to accommodate a filter element having no center supporting tube. This allows a filter element to be constructed solely of combustible material, thus allowing the filter element to be completely incinerable.
2. Description of the Related Art
In industrial filtering applications, often the material which is to be filtered contains contaminants which must be removed and disposed of as hazardous waste. One of the acceptable ways of disposing of many types of hazardous waste is incineration performed by a licensed hazardous waste disposal facility.
One problem which previous filter systems present is that the filter element onto which the contaminates adhere have generally contained a metal or other rigid, non-combustible center support member. In order to incinerate these filter elements, the support member must either be manually removed from the filter element prior to the incineration and then separately disposed of as hazardous waste or, alternately, the entire filter element must be shredded prior to incineration.
Removal of the center support member prior to incineration presents safety problems to the workers performing the removal, adds to the cost of disposal, and increases the risk of liability to the company generating the waste. This increase in risk of liability is due to the fact that the removed support members are considered hazardous waste which must be disposed of in a licensed hazardous waste landfill. As a contributor to a hazardous waste landfill which may sometime be declared a Superfund site, the generating company, the disposal company and any transporting company which was employed to deliver the support members to the landfill, may all face future liability for the disposal. Thus, both the generating company and the disposal company would prefer to avoid this option since under current hazardous disposable waste laws, they remain liable for their hazardous waste from "cradle-to-grave".
On the other hand, in order for the entire filter element to be incinerated, a disposal facility must first be located which has the capability of shredding materials prior to incineration. Second, since the non-combustible elements of the filter element will pass through the hazardous waste incinerator and will exit as solid waste which is normally disposed of as hazardous waste in a hazardous waste landfill, the generating company retains the potential Superfund liability with this option also. This is true despite the fact that the material is not hazardous waste, since all contributors to a landfill which later becomes a Superfund site are liable for ensuing cleanup costs regardless of the types of materials they contributed. For these reasons, shredding and incinerating the entire filter elements is also an unattractive option.
The only other viable option available for disposal of most filter elements is to bury the entire filter element in a hazardous waste landfill. This option is costly and increases the risk of Superfund liability since the containers in which the filter elements are sealed for burial will eventually be breached by the soil's natural chemical processes, thus, releasing the contaminants into the soil.
Thus, to avoid potential liability, it is desirable to have completely incinerable filters. The present invention addresses this problem by providing a filter system having a permanent center tube assembly onto which fully incinerable filter elements may be replaceably attached.
SUMMARY OF THE INVENTION
The present invention briefly is a filter system having an elongated hollow apertured center tube assembly around which fully incinerable filter elements may be replaceably secured. The center tube assembly may be composed of one or more interlocking tube sections which are attached to each other end-to-end by means of an intermediate connecting member. Each of the interlocking tube sections is composed of an interlocking upper female tube and a corresponding lower male tube. A bottom end of the tube assembly abuts a filter attachment means and is held in vertical alignment therewith by means of a central rod which secures to the filter attachment means and extends upwardly therefrom, passing sequentially through openings provided in a bottom flange member located at the bottom end of the center tube assembly, a hub portion provided on each intermediate connecting member for center tube assemblies comprised of more than one interlocking tube section, and a top flange member located at a top end of the center tube assembly. A jam nut tightens onto a threaded portion provided on a top end of the rod, abutting the top flange member in order to secure the center tube assembly to the filter attachment means. The filter element is then slid down around the center tube assembly. A yoke provided with a central opening through which the threaded portion of the rod passes, is secured to the filter system by tightening a nut onto the threaded portion of the rod so that the nut tightens against washers which abut the yoke. As the nut is tightened, a compressible bottom sealing gasket provided on a bottom end of the filter element seals the filter element to the filter attachment means and a compressible top sealing gasket provided on a top end of the filter element seals the filter element to the yoke.
In use, a medium to be filtered passes inwardly through a pleated filter medium provided on the filter element, through the apertured centered tube assembly, then downwardly through the opening in the bottom flange member which communicates with a fluid passageway provided in the filter attachment means as a means for the filtered medium to exit the filter system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation of a filter system constructed according to a preferred embodiment of the present invention.
FIG. 2 is a cross-sectional view taken along line 2--2 of FIG. 1.
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 1.
FIG. 4 is a top plan view of the filter system taken along line 4--4 of FIG. 1.
FIG. 5 is a front elevation of a bottom flange removed from the filter system of FIG. 1.
FIG. 6 is a top plan view of the bottom flange taken along line 6--6 of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and initially to FIG. 1, there is illustrated a filter system 10 constructed according to a preferred embodiment of the present invention.
The filter system 10 is provided with a vertically oriented central rod 12, having a bottom end 14, which is attached by means of a nut 15 or otherwise to a filter attachment means 16, and a top end 18 provided with a threaded portion 20. The filter attachment means 16 is provided with a fluid passageway 22 therethrough. An upwardly oriented inner retaining lip 24 is provided concentrically around the fluid passageway 22. The filter attachment means 16 is provided with a horizontally oriented ledge 25 attached circumferentially and extending outwardly from the inner retaining lip 24. An upwardly oriented outer retaining lip 26 is provided on the ledge 25 of the filter attachment means 16 so that the outer retaining lip is spaced away from the inner retaining lip 24 and is spaced away from an outer edge 26 of the ledge 25.
An elongated apertured center tube assembly 30, having a top end 32 and a bottom end 34, attaches by means of a lower end 35 of a bottom flange member 36 provided on the bottom end 34 of the center tube assembly 30 to the filter attachment means 16 so that the lower end (35) rests between the inner and outer retaining lips 24 and 26. Bottom flange member 36 is provided with a central opening 37 which allows communication between the center tube assembly 30 and the fluid passageway 22 of the filter attachment means 16.
The center tube assembly 30 is composed of at least one interlocking tube section 38. The filter system 10, as illustrated in FIG. 1, employs two interlocking tube sections 38. Although not illustrated, the present invention also includes filter systems 10 employing one or more than two interlocking tube sections 38. Each interlocking tube section 38 is composed of a lower male tube 40 and an upper female tube 42. The tubes 40 and 42 are held together by means of ears 41 provided on an upper end 43 of each the lower male tubes 40 that engage corresponding openings 44 provided in a lower end 45 of each of the female tubes 42.
Each of the male tubes 40 is provided with a lower end 46. When the center tube assembly 30 is composed of only one tube section 38, the lower end 46 of the solitary male tube 40 serves as the bottom end 34 of the center tube assembly 30 and, as such, secures to an upper end 48 of the bottom flange member 36. As best seen in FIGS. 1, 5 and 6, the upper end 48 of bottom flange member 36 is provided with an upwardly oriented section 50 of decreased external diameter, and the lower end 46 of the lower male tube 40 is provided with a downwardly oriented section 52 of increased internal diameter so that the upwardly oriented section 50 telescopically receives the downwardly oriented section 52. The upwardly oriented section 50 is provided with ears 54 that engage corresponding openings 55 (visible in the upper most tube section 38 in FIG. 1) provided in the downwardly oriented section 52 in order to secure the bottom end 34 of the central tube assembly 30 to the bottom flange member 36.
As illustrated in FIG. 1, two or more tube sections 38 can be attached concentrically end-to-end by employing intermediate connecting members 56. Each of the intermediate connecting members 56 has an upwardly oriented upper end 58, a downwardly oriented lower end 60, and a middle portion 62 located between the two ends 58 and 60. Collectively, the ends 58 and 60 and the middle portion 62 comprise a circumferential flange portion of each of the intermediate connecting members 56. Referring also to FIG. 3, the middle portion 62 is provided with spokes 64 oriented inwardly and attached centrally to a central hub 66. The central hub is provided with an opening 68 therethrough for receiving the rod 12.
Each of the lower ends 60 is decreased in external diameter, and an upper end 70 provided on each of the female tubes 42 is decreased in internal diameter so that the lower ends 60 are telescopically received by the upper ends 70 of the interlocking tube section 38 located immediately below. Each of the upper ends 70 is provided with openings 72 for receiving corresponding ears 73 provided on each of the lower ends 60 to secure the intermediate connecting member 56 to the tube section 38 located immediately below the intermediate connecting member 56.
Likewise, each of the upper ends 58 is decreased in external diameter so that the upper ends 58 telescopically receive the downwardly oriented sections 52 provided on the lower ends 46 of the male tube 40 in the tube section 38 located immediately above. Similarly, each of the upper ends 58 is provided with ears 74 that engage the openings 55 provided in the downwardly oriented section 52 of the male tube 40 of the tube section 38 located immediately above in order to secure together the intermediate connecting member 56 and the tube section 38 immediately above.
The upper end 70 of the female tube 42 located in the upper most tube section 38 of the filter system 10 is telescopically received by a lower end 76 having a reduced external diameter which is provided on a top flange member 78. The top flange member 78 is removably secured to the center tube assembly 30 and, therefore, the top flange member 78 does not have any ears for engaging the openings 72 provided on the upper end 70 of the female tube 42 in the uppermost tube section 38.
The top flange member 78, shown in FIGS. 1 and 2, is provided with a continuous upper end 80 that extends inwardly and is provided with a central opening 82 therethrough for receiving the rod 12. Adjacent the central opening 82, the upper end 80 of flange member 78 forms an upwardly facing depression 84 into which a jam nut 86 is positioned when the jam nut 86 is tightened onto the threaded portion 20 of the rod 12 in order to secure the center tube assembly, 30 to the filter attachment means 16.
The upwardly facing depression 84 is provided with a plurality of pressure relief openings 88 that communicate through the top flange member 78 and that permit liquids and gases from becoming trapped in the depression 84.
Once the center tube assembly 30 has been secured to the filter attachment means 16, a hollow pleated filter element 90, having a top end 91 and a bottom end 92, is lowered around the center tube assembly 30. The pleated filter element 90 comprises a top ring 93 to which a top sealing gasket 94 is attached, an opposite bottom ring 96 to which a bottom sealing gasket 98 is attached, and a pleated filter medium 100 extending between and sealing to the top and bottom rings 93 and 96. When used with the filter system 10 which has the center tube assembly 30 attached thereto, the filter element 90 does not require a center support tube to be incorporated in the filter element 90. Therefore, the filter element 90 can be made solely of combustible materials that can be disposed of by incinerating.
Referring now to FIGS. 1 and 4, the filter element 90 is lowered into place so that the bottom sealing gasket 98 engages the ledge 25 of the filter attachment means 16. Once the filter element 90 is in place, a yoke 102 provided with a central opening 104 therethrough is placed over the top end 18 of the rod 12 so that the rod 12 extends through the opening 104. The yoke 102 is then lowered on the rod 12 until its outer peripheral area 103 is adjacent the top flange member 78 and engages the top sealing gasket 94. A compressible washer 106 is next placed onto the threaded portion 20 adjacent the yoke 102. A second washer 108 is then placed between the compressible washer 106 and a nut 110. The nut 110 is tightened against the washers 106 and 108, thus compressing the top and bottom sealing gaskets 94 and 98 and, thereby, sealing the filter element 90 to the filter attachment means 16 on the bottom end 92 and to the yoke 102 on the top end 91.
In use, a medium to be filtered (not illustrated) passes through the pleated filter element 90, then through the apertured center tube assembly 30 before exiting the filter assembly 10 via the fluid passageway 22 of the filter attachment means 16. The center tube assembly 30 supports the filter element 90, enabling it to withstand differential pressure exerted on it by the medium to be filtered (not illustrated).
When the filter element 90 becomes clogged, flow of the medium to be filtered (not shown) is discontinued in order to take the filter system 10 out of service. After the filter system 10 is out of service, the nut 110 is removed from the red 12 and the washers 106 and 108 and the yoke 102 are removed. The filter element 90 is then slipped upward and removed from the center tube assembly 30. A fresh filter element 90 is then inserted around the center tube assembly 30 and the yoke 102, the washers 106 and 108 are replaced, and the nut 110 is re-tightened to seal the filter element 90 to the filter attachment means 16 and the yoke 102. The filter system 10 is then ready to be placed back in service.
The claims and the specification describe the invention presented and the terms that are employed in the claims draw their meaning from the use of such terms in the specification. The same terms employed in the prior art may be broader in meaning than specifically employed herein. Whenever there is a question between the broader definition of such terms used in the prior art and the more specific use of the terms herein, the more specific meaning is meant.
While the invention has been described with a certain degree of particularity, it is manifest that many changes may be made in the details of construction and the arrangement of components without departing from the spirit and scope of this disclosure. It is understood that the invention is not limited to the embodiments set forth herein for purposes of exemplification, but is to be limited only by the scope of the attached claim or claims, including the full range of equivalency to which each element thereof is entitled.
|
A replaceable element fluid filter is provided that has a rigid apertured center tube which is attached to a fluid outlet. The center tube is formed of a plurality of sections that fit together to achieve the desired overall length. A rod of selectable length is received within the center tube to retain the center tube in rigid position in communication with a fluid outlet. Once the center tube assembly is secured to the fluid outlet, a tubular filter element is replaceably secured around the center tube. By incorporating a rigid center tube, the tubular filter element can be constructed so that it does not require a self contained supporting structure. By varying the number of sections of the center tube and the length of the rod, tubular filter elements of various lengths may be employed.
| 1
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of earlier filed U.S. application Ser. No. 10/185,290 filed Jun. 27, 2002, the contents of which are incorporated herein by reference; which earlier filed application claims the benefit of U.S. Provisional Application Serial No. 60/301,962, filed on Jun. 29, 2001, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention dates to delivery methods, systems and components thereof for use with hazardous or toxic pharmaceutical substances, and especially to delivery and injection methods, systems and components thereof for use with radiopharmaceutical substances.
[0004] 2. Prior Art
[0005] As used herein, the term “pharmaceutical” refers to any substance to be injected or otherwise delivered, into the body (either human or animal) in a medical procedure and includes, but is not limited to, substances used in imaging procedures (for example, contrast media) and therapeutic substances. A number of such pharmaceutical substances pose a danger to both the patient and the personnel administering the substance if not handled and/or injected properly. Examples of hazardous pharmaceuticals include, but are not limited to, radiopharmaceuticals, biological pharmaceuticals, chemotherapeutic pharmaceuticals and gene therapeutic pharmaceuticals.
[0006] Examples of use of a radiopharmaceutical include positron emission tomography (PET) and single-photon emission computerized tomography (SPECT), which are noninvasive, three-dimensional, imaging procedures that provide information regarding physiological and biochemical processes in patients. The first step in producing PET images or SPECT images of, for example, the brain or another organ, is to inject the patient with a dose of the radiopharmaceutical. The radiopharmaceutical is generally a radioactive substance that can be absorbed by certain cells in the brain or other organ, concentrating it there. For example, fluorodeoxyglucose (FDG) is a normal molecule of glucose, the basic energy fuel of cells, attached a radionuclide or radioactive fluor. The radionuclide is produced in a cyclotron equipped with a unit to synthesize the FDG molecule.
[0007] Cells (for example, in the brain) which are more active in a given period of time after an injection of FDG, will absorb more FDG because they have a higher metabolism and require more energy. The radionuclide in the FDG molecule suffers a radioactive decay, emitting a positron. When a positron collides with an electron, an annihilation occurs, liberating a burst of energy in the form of two beams of gamma rays in opposite directions. The PET scanner detects the emitted gamma rays to compile a three dimensional image.
[0008] In that regard, after injecting the radiopharmaceutical, the patient is typically placed on a moveable bed which slides by remote control into a circular opening of the scanner referred to as the gantry. Positioned around the opening, and inside the gantry, there are several rings of radiation detectors. Each detector emits a brief pulse of light every time it is struck with a gamma ray coming from the radionuclide within the patient's body. The pulse of light is amplified, by a photomultiplier, and the information is sent to the computer which controls the apparatus.
[0009] The timing of injection is very important. After the generation of the radiopharmaceutical, a countdown begins. After a certain time, which is a function of the half-life of the radionuclide, the radiation level of the radiopharmaceutical dose falls exactly to a level required for the measurement by the scanner. In current practice, the radiation level of the radiopharmaceutical volume or dose is typically measured using a dose calibrator. Using the half-life of the radionuclide, the time that the dose should be injected to provide the desired level of radioactivity to the body is calculated. When that time is reached, the radiopharmaceutical dose is injected using a manually operated syringe.
[0010] Most PET radionuclides have short half-lives. Under proper injection procedures, these radionuclides can be safely administered to a patient in the form of a labelled substrate, ligand, drug, antibody, neurotransmifter or other compound normally processed or used by the body (for example, glucose) that acts as a tracer of specific physiological and biological processes.
[0011] Excessive radiation to technologists and other personnel working in the scanner room can pose a significant risk, however. Although the half-life of the radiopharmaceutical is rather short and the applied dosages are themselves not harmful to the patient, administering personnel are exposed each time they work with the radiopharmaceuticals and other contaminated materials under current procedures. Constant and repeated exposure over an extended period of time can be harmful.
[0012] A number of techniques used to reduce exposure include minimizing the time of exposure of personnel, maintaining distance between personnel and the source of radiation and shielding personnel from the source of radiation. In general, the radiopharmaceutical is typically delivered to a nuclear medicine facility from another facility equipped with a cyclotron in, for example, a lead-shielded container. Often, the radiopharmaceutical is manually drawn from such containers into a shielded syringe. See, for example, U.S. Pat. No. 5,927,351 disclosing a drawing station for handling radiopharmaceuticals for use in syringes. Remote injection mechanisms can also be used to maintain distance between the operator and the radiopharmaceutical. See, for example, U.S. Pat. No. 5,514,071, disclosing an apparatus for remotely administering radioactive material from a lead encapsulated syringe.
[0013] In one procedure, the radiopharmaceutical is injected into tubing that is coiled within a lead container. Typically, the shielded syringe used to inject the radiopharmaceutical is disconnected and replaced by a larger syringe, filled in most cases with saline, for injection into the body and flush. By emptying the second syringe, the radiopharmaceutical is flushed through the shielded, coiled tubing in the container and injected into the person, to be scanned. An excess volume of saline supplies a flushing function.
[0014] Although substantial effort is made to reduce exposure of administering and other personnel to harmful radiation, some exposure is experienced under current procedures. Being in the injection room longer than necessary is thus to be avoided. Moreover, the cumulative radiation exposure resulting from multiple injection procedures must be closely monitored to avoid overexposure. Indeed, personnel that administer radiopharmaceuticals are typically periodically rotated out of such duties to reduce the risk of overexposure.
[0015] In addition to the difficulties introduced by the hazardous nature of radiopharmaceuticals, the short half-lives of such radiopharmaceutical further complicate the administration a proper dosage to a patient. As discussed above, initial calibration of radioactivity is often made and the injection is then timed so that a dose of the desired level of radioactivity to the body is delivered (as calculated from the half-life of the radiopharmaceutical). See, for example, U.S. Pat. No. 4,472,403 in which a motor driven syringe is controlled to inject a quantity of a radiopharmaceutical stored in the syringe by calculating the injection quantity based upon the half-life of the radiopharmaceutical and the delay before injection.
[0016] Radiation detectors have also been placed upon syringe shields and in line with the radiopharmaceutical delivery system. For example, U.S. Pat. No. 4,401,108 discloses a syringe loading shield for use during drawing, calibration and injection of radiopharmaceuticals. The syringe shield includes a radiation detector for detecting and calibrating the radioactive dosage of the radiopharmaceutical drawn into the syringe. U.S. Pat. Nos. 4,562,829 and 4,585,009 disclose strontium-rubidium infusion systems and a dosimetry system for use therein. The infusion system includes a generator of the strontium-rubidium radiopharmaceutical in fluid connection with syringe for supplying pressurized saline. Saline pumped through the strontium-rubidium generator exits the generator either to the patient or to waste collection. Tubing in line between the generator and the patient passes in front of a dosimetry probe to count the number of disintegrations which occur. As the flow rate through the tubing is known, it is possible to measure the total activity delivered to the patient (for example, in milliCuries). Likewise, radiation measurements have been made upon blood flowing through the patient. For example, U.S. Pat. No. 4,409,966 discloses shunting of blood flow from a patient through a radiation detector.
[0017] The danger to administering personnel and other difficulties that arise from the nature of hazardous pharmaceuticals such as radiopharmaceuticals often affect the quality and safety of the injection procedure. For example, given the care that must be taken to prevent radiation overexposure (including limiting the duration of injection procedures), the concern with properly timing an injection and the need to prevent the creation of radioactive wastes, it is often difficult to properly eliminate air from all fluid paths before an injection begins.
[0018] It is thus very desirable to develop devices, systems and methods through which toxic or hazardous pharmaceuticals (far example, radiopharmaceuticals) can be administered in controlled manner to enhance their effectiveness and patient safety, while reducing exposure of administering personnel to such hazardous pharmaceuticals.
SUMMARY OF THE INVENTION
[0019] In one aspect, the present invention provides a method of injecting a hazardous pharmaceutical comprising the steps of: connecting a source of flushing fluid to a first port of a fluid delivery set; connecting a pressurizing unit of a powered injector system (including a powered injector and the pressurizing unit) to a second port of the fluid delivery set; purging air from the fluid delivery set; and, after purging air from the fluid delivery set, connecting a third port of the fluid delivery set to a source of the hazardous pharmaceutical. The fluid delivery set can, for example, include a valve system or assembly to control flow of fluid through the fluid delivery set. The ports of the fluid delivery set can, for example, include luer connectors as known in the medical arts to form a removable, secure and generally sealed connection
[0020] The method preferably further includes the steps of (i) removably connecting a disposable fluid path that is connectable (via, for example, a catheter) to a patient to the fluid delivery set and (ii) purging air from the disposable fluid path before connecting the fluid delivery set to the source of hazardous pharmaceutical.
[0021] By removing air from the fluid delivery set and the patient fluid path before any connection is made to the source of hazardous pharmaceutical, exposure of administering personnel to the hazardous pharmaceutical to that point is eliminated. Connecting the fluid delivery set to the source of pharmaceutical can be automated or otherwise accomplished remotely (for example, with use of an extending or robotic arm as known in the machine and robotic arts) to prevent exposure during that connection.
[0022] The pressurizing unit can, for example, be a syringe in operative connection with the powered injector. In the case that the pressurizing unit is a syringe, the method can further include the steps of drawing hazardous pharmaceutical into the syringe and injecting the hazardous pharmaceutical through the fluid delivery set and the disposable fluid path. Using a powered injector having a control unit removed in distance or shielded from the position of the syringe, fluid delivery set and fluid path prevents exposure of operating/administering personnel to the hazardous pharmaceutical. The method preferably further includes the step of flushing the fluid delivery set and the disposable fluid path after injection using the flushing fluid (for example, saline and/or another biologically acceptable flushing agent). A powered injector can also be used with a saline syringe in a similar manner as described above to limit exposure of operating personnel to the hazardous pharmaceutical.
[0023] In the case that the hazardous pharmaceutical is a radiopharmaceutical, the method can further include the step of measuring the level or dosage of radioactivity of the radiopharmaceutical injected. Preferably, the level of radioactivity or dosage is measured very near in time or simultaneously with delivery of the radiopharmaceutical to provide an accurate measurement of the dosage delivered. For example, the level of radioactivity can be measured by positioning the syringe within a dose calibrator. The level of radioactivity can also measured by placing a radioactivity detector in operative connection with a line through which the radiopharmaceutical is dispensed or delivered.
[0024] In another aspect, the present invention provides a system for delivery of a hazardous pharmaceutical including: a syringe in operative connection with a powered injector and a protective container to enclose the syringe during operation thereof. The protective container is constructed or adapted to protect personnel from detrimental effects of the pharmaceutical. The system preferably also includes at least one source of flushing fluid; a fluid path adapted to connect to a patient; at least one source of the pharmaceutical; and a fluid delivery set. The fluid delivery set preferably includes a valve assembly to which the syringe, the source of flushing fluid, the fluid path and the source of pharmaceutical are removably connectable.
[0025] The valve assembly preferably provides flow control through the fluid delivery set such that operator contact with the fluid delivery set is not required after connection of the source of pharmaceutical to the fluid delivery set. The valve assembly also preferably provides flow control through the fluid delivery set such that the entire fluid delivery set can be purged of air with the syringe and the source of flushing fluid in fluid connection with the valve assembly before the source of pharmaceutical is connected to the fluid delivery set. In one embodiment, the valve assembly includes a bypass line in continuous fluid connection between the source of flushing fluid and the fluid path.
[0026] In the case that the pharmaceutical is a radiopharmaceutical, the protective container can, for example, be a component of a dose calibrator adapted to measure the level of radioactivity of the pharmaceutical within the syringe. In one embodiment, the syringe is connected to the powered injector via an extending adapter that preferably extends from the powered injector when connected thereto to position the syringe within the protective container.
[0027] The adapter can, for example, include an injector attachment member to attach the adapter to a powered injector and a plunger extension fixed in position relative to a powered injector. The plunger extension preferably has a plunger attachment member to attach to a plunger of the syringe. In one embodiment, the adapter also includes a syringe carriage slidably attached to the adapter. The syringe carriage includes a syringe attachment member to removably attach a syringe thereto so that a barrel of a syringe can be moved relative to a plunger thereof to control fluid flow into and out of a syringe.
[0028] The above embodiment of an adapter facilitates orientation of the syringe tip or exit of the syringe directed toward the powered injector when the syringe is attached to the syringe attachment member. This orientation can facilitate purging of air from the syringe when the syringe is placed within, for example, a dose calibrator positioned below the injector. In that regard, lead-shielded dose calibrators are often relatively large and heavy and thus often positioned most easily near the floor. Moreover, this relative positioning of the injector and dose calibrator assists in limiting exposure of operating/administering personnel by directing any waves of radiation escaping from the dose calibrator upward to the ceiling of the room. Moving the syringe barrel relative to the syringe plunger in the manner described in the above embodiment facilitates use of commercially available injectors and syringes for use therewith by eliminating the need to change/recalibrate the direction and distance the injector drive member must advance or retract to complete a desired operation.
[0029] In another aspect, the present invention provides a method of using a powered injector system to inject a radiopharmaceutical into a body including the steps of: attaching an extending adapter to the front end of the powered injector; the adapter including an injector attachment to place the adapter in operative connection with the powered injector, the adapter also including a syringe attachment to attach a syringe to the adapter to place the syringe in operative connection with the powered injector; and extending the adapter into a radiation shield. As discussed above, the radiation shield can form part of a dose calibrator to measure the radioactivity of radiopharmaceutical within the syringe. In one embodiment, the exit of the syringe is oriented upward relative to the opposite end of the syringe when the syringe is positioned within the dose calibrator to facilitate purging of air from the syringe. As discussed above, the opening through which the syringe passed to enter the dose calibrator is preferably oriented in a direction (for example, upward toward the ceiling) to decrease the likelihood of exposure of personnel to any radiation waves exiting the dose calibrator during use thereof.
[0030] In a further aspect, the present invention provides an adapter for use with a powered injector to attach a syringe to the powered injector including: an injector attachment member to attach the adapter to a powered injector and a syringe attachment member spaced from the injector attachment member by a sufficient distance to position a syringe attached to the syringe attachment member within a radiation dose calibrator. Preferably, the adapter facilitates use of commercially available injector systems with commercially available dose calibrators without the requirement of substantial and/or expensive modification thereto.
[0031] In another aspect, the present invention provides an adapter for use with a powered injector to attach a syringe to the powered injector including an injector attachment member to attach the adapter to a powered injector and a plunger extension fixed in position relative to a powered injector. The plunger extension bas a plunger attachment member to attach to a plunger of the syringe. The adapter further includes a syringe carriage slidably attached to the adapter and including a syringe attachment member to removably attach a syringe thereto so that a barrel of the syringe can be moved relative to a plunger thereof to control fluid flow into and out of the syringe. As discussed above, the syringe can be oriented with a syringe tip thereof directed toward the powered injector when attached to the syringe attachment member.
[0032] In another aspect, an adapter includes an attachment member to removably attach the adapter to a powered injector and a syringe carriage slidably attached to the attachment member. The syringe carriage includes a syringe attachment member to which a syringe can be removably attached. The adapter further includes an end member attached a fixed distance from the attachment member. The end member has a plunger extension attached to the end member and extending toward the injector. The plunger extension includes a plunger attachment member on an end thereof opposite the end attached to the end member. The syringe carriage is adapted to move a barrel of the syringe relative to a plunger of the syringe when a syringe is attached to the syringe attachment member and a plunger thereof is attached to the plunger extension member.
[0033] In another aspect, the present invention provides a shield for use with a radiopharmaceutical including a housing that is impenetrable by radioactive energy from the radiopharmaceutical. The shield also includes at least one opening in the housing through which an article containing the radiopharmaceutical which is positioned within the housing can be viewed. The opening is in visual alignment with a reflective surface in which a viewer can view a reflection of the article. The opening is positioned within the housing such that there is no direct line between the viewer and the article that is not shielded by a portion of the housing. Because radiation energy from radiopharmaceuticals travel in straight lines, the viewer is shielded from exposure to radiation.
[0034] In a further aspect, the present invention provides a method of injecting a. radiopharmaceutical into a body including the steps of positioning a pressurizing unit or device containing a first volume of the radiopharmaceutical within a dose calibrating unit adapted to measure the level of radioactivity of the radiopharmaceutical; and injecting a second volume of the radiopharmaceutical. The second volume is determined through measurement by the dose calibrating unit to provide a desired level of radioactivity. The second volume can, for example, be less than the first volume. In one embodiment, the pressurizing chamber is a syringe in fluid connection with a powered injector.
[0035] In another aspect, the present invention provides a kit for injecting a hazardous pharmaceutical into a body including: a fluid path adapted to connect to a patient; and a fluid delivery set. The fluid delivery set includes a valve assembly to which a pressurizing unit, a source of flushing fluid, the fluid path and a source of the pharmaceutical are removably connectable. The valve assembly provides flow control through the fluid delivery set such that operator contact with the fluid delivery set is not required after connection of the source of pharmaceutical to the fluid delivery set. The valve assembly also preferably provides flow control through the fluid delivery set such that the entire fluid delivery set can be purged of air with the syringe and the source of saline in fluid connection with the valve assembly before the source of pharmaceutical is connected to the fluid delivery set.
[0036] In still a further aspect, the present invention provides a method of injecting a radiopharmaceutical into a patient comprising the steps of: connecting a powered pressurizing device that is controlled without intimate or close contact by an operator (far example, remotely controlled, automated or preprogrammed so that the operator is not within a radiation field of a dangerous level) to a valve assembly of a fluid delivery set; connecting at least one source of a flushing fluid to the valve assembly; connecting a patient fluid path to the valve assembly, the patient fluid path terminating in a patient connector; connecting a source of a ready-made (that is, prepared earlier for example, in an offsite cyclotron) radiopharmaceutical to the valve assembly; and controlling the valve assembly at least during injection of the hazardous pharmaceutical such that operator presence in the vicinity of the radiopharmaceutical is not required. In general, a dose to an individual decreases with the square of the distance from the radiation source. Thus, close operator contact with the pressurizing device, fluid delivery set and other components of the fluid delivery system is not required when the radiopharmaceutical is present in the fluid delivery system. Moreover, shielding as described above can also be used to prevent exposure. The valve assembly can also be controlled without intimate contact by an operator (for example, remotely controlled, automated or preprogrammed).
[0037] In general, the present invention provides for administration or delivery of a toxic or hazardous pharmaceuticals (for example, radiopharmaceuticals) in a controlled manner to enhance the effectiveness of the pharmaceutical and to enhance patient safety (as compared to current procedures and equipment for delivering such pharmaceuticals), while reducing exposure of administering personnel to the hazardous pharmaceuticals. In general, commercially available injector systems are readily adaptable for use in the present invention without substantial or expensive modification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] [0038]FIG. 1A illustrates a schematic representation of an embodiment of a system of the present invention.
[0039] [0039]FIG. 1B illustrates a top cross-sectional view of an embodiment of a shielded container for a fluid delivery set of the present invention.
[0040] [0040]FIG. 1C illustrates a side cross-sectional view another embodiment of a shielded container for a fluid delivery set of the present invention.
[0041] [0041]FIG. 2A illustrates a perspective view an embodiment of an injector and a syringe adapter of the stem of the present invention.
[0042] [0042]FIG. 2B illustrates a perspective view of injector control units used in connection with the injector of the present invention.
[0043] [0043]FIG. 3 illustrates a perspective view of the system of the present invention in which the injector head and syringe adapter have been lowered so that the syringe is positioned within the dose calibration unit.
[0044] [0044]FIG. 4A illustrates a perspective view of the adapter of FIG. 2A detached from the injector with the syringe attached thereto.
[0045] [0045]FIG. 4B illustrates a perspective view of the adapter of FIG. 2A detached from the injector with the syringe detached therefrom.
[0046] [0046]FIG. 4C illustrates a side cross-sectional view a portion of the system of FIGS. 1 through 4B.
[0047] [0047]FIG. 5A illustrates a side cross-sectional view of an embodiment of the present invention in which dose calibration is provided by placing a pressurizing device and a source of radiopharmaceutical within a shielded dose calibrator.
[0048] [0048]FIG. 5B illustrates a side cross-sectional view of an embodiment of the present invention in which dose calibration is provided by placing a source of radiopharmaceutical within a shielded dose calibrator.
[0049] [0049]FIG. 5C illustrates a side cross-sectional view of an embodiment of the present invention in which dose calibration is provided by placing a radiation detector in line between a pressurizing device and a source of radiopharmaceutical within a shielded close calibrator.
[0050] [0050]FIG. 5D illustrates a side cross-sectional view of an embodiment of the present invention in which dose calibration is provided by placing a radiation detector in line with the exit line of a pressurizing device.
DETAILED DESCRIPTION OF THE INVENTION
[0051] As illustrated in FIG. 1A, in one embodiment of the present invention, a system 10 includes a fluid delivery set or system 15 including a valve system 16 that provides a fluid connection for a saline source 20 (for example, a syringe), a source 40 of a pharmaceutical to be injected into a patient, a pressurizing chamber or unit for the pharmaceutical (for example, a syringe 60 in fluid connection with a powered injector 70 in the embodiment of FIG. 1) and a fluid path set 80 that is connectable to the patient (via, for example, tubing terminating in a catheter 100 ). In general, the fluid delivery set 16 , valve system 15 and other elements of the present invention enable purging of air from the system, filling of syringe 60 with the pharmaceutical, delivery of the pharmaceutical (for example, injecting the pharmaceutical into the patient) via syringe 60 , and providing a saline flush, while minimizing or eliminating exposure of administering or operating personnel to the detrimental effects of the pharmaceutical and minimizing or eliminating creation of contaminated waste. Moreover, fluid delivery set 15 and other elements of the present invention also facilitate safe delivery of the pharmaceutical to multiple destinations (for example, injection into a series patients).
[0052] In the embodiment of FIG. 1, valve system 16 includes a three-way stopcock 30 including a first port 32 that is in fluid connection with saline syringe 20 . As second port 34 of stopcock 30 is in fluid connection with source 40 of a toxic or hazardous pharmaceutical (for example, a radiopharmaceutical). Source 40 of the pharmaceutical is preferably enclosed within a container 44 that is designed to reduce the risk of contamination of personnel administering the pharmaceutical. For example, in the case of a radiopharmaceutical, the container can fabricated from lead or tungsten to substantially prevent exposure of such personnel to undesirably high levels of radiation.
[0053] A third port 36 of stopcock 30 is in fluid connection with, for example, a dual check valve 50 . The flow through stopcock 30 is controlled via control 38 . A first port 52 of dual check valve 50 is in fluid connection with syringe 60 that is preferably in operative connection with powered injector 70 . A second port 54 of dual check valve 50 its preferably in fluid connection with patient fluid path set 80 that includes, for example, flexible tubing 90 connected to catheter 100 . Preferably, patient fluid path set 80 is disposable on a per patient basis to reduce the likelihood of cross-contamination when system 10 is used for injection of fluids into multiple patients. Patient fluid path set 80 is preferably in fluid connection with second port 54 of dual check valve 50 via a one-way check valve 110 to further reduce the likelihood of cross-contamination.
[0054] Preferably, saline source 20 is also in fluid connection with fluid path set 80 via bypass tubing or conduit 120 of valve system 16 to provide, for example, flush and KVO (keep vein open) functions on demand without having to adjust control 38 of valve system 15 . In the embodiment of FIG. 1, a tee 130 is positioned between saline source 20 and dual check valve 30 . A side port 132 of tee 130 is in fluid connection with bypass tubing 120 . Bypass tubing 120 is preferably in fluid connection with check valve 110 (an thereby with fluid path set 80 ) via a one-way check valve 140 .
[0055] In injection procedures and other fluid delivery operations in which non-hazardous pharmaceuticals are delivered, purging air from the entire fluid path (including, the fluid path between a source of the pharmaceutical and the delivery point) typically includes the forcing an amount of the pharmaceutical through the fluid path to, for example, a waste receptor before beginning the procedure (for example, before insertion of a catheter into the patient). However, in the case of a hazardous pharmaceutical such as a radiopharmaceutical, it is very desirable to minimize or eliminate the creation of waste pharmaceutical. Moreover, as discussed above, it is also preferably in, the case of a hazardous pharmaceutical to minimize exposure of administering personnel to the pharmaceutical. The present invention, thus preferably enables purging of air from the entirety of fluid delivery set 15 (and preferably, also from patient fluid path set 80 ) before connection of fluid delivery set 16 to pharmaceutical source 40 . In this manner, exposure of administering personnel to hazardous materials during purging is eliminated and no hazardous waste is generated.
[0056] After connecting fluid delivery set 16 , which is fluid filled and purged of air, to pharmaceutical source 40 , air can be introduced into fluid delivery system 10 from pharmaceutical source 40 . Thus, precautions are preferably taken as known in the art to reduce the likelihood of introduction of air into system 10 from pharmaceutical source 40 . Moreover, a bubble detector 150 can be placed in communication with line 46 to detect if air is drawn from pharmaceutical source 40 . Examples of a bubble detectors suitable for use in the present invention include the BDF/BDP series ultrasonic air bubble detectors available from Introtek of Edgewood, N.Y.
[0057] In, the case that it is desirable to purge system 10 (for example, in the case that air is found in one of the fluid path lines) a waste container 160 (which is preferably shielded) is preferably provided. In the embodiment of FIG. 1A waste container 160 is in fluid connection with a control valve 170 (similar in operation to control valve 30 ) which is in line just before check valve 110 . Control valve 170 can be controlled remotely or automated to reduce likelihood of exposure of operating personnel to the toxic pharmaceutical. It is also possible, for example, to provide valve 50 with control in a manner known to those skilled in art such that fluid can be purged back to source 40 . In general, system 10 is purged using syringe 60 and/or saline source 10 as described below.
[0058] During operation of system 10 , saline syringe 20 (which can be a hand syringe or a syringe powered by an injector 24 ) is first filled with saline. Saline syringe 20 is then connected to valve system 16 of fluid delivery set 15 via first port 32 on three-way stopcock 30 . Saline syringe 20 is preferably used to purge air from system 10 . Saline syringe 20 also provides a flush to patient fluid path set 80 after injection of pharmaceutical(s) to ensure that substantially all the pharmaceutical is injected into the patient and to ensure that very little if any of the toxic or hazardous pharmaceutical remains, for example, within fluid path set 80 .
[0059] Syringe 60 is attached to injector 70 . In the case of injection of a radiopharmaceutical, at least syringe 60 of injector 70 is preferably enclosed within a shielded container during an injection procedure. In one embodiment, the shielded container is a radiation dose calibration unit 200 as discussed in further detail below. Air is first preferably expelled from syringe 60 by advancing plunger 62 of syringe 60 toward syringe tip 64 . Syringe 60 is then connected to dual check valve 50 of valve system 16 via first port 42 . Patient fluid path set 80 is connected to valve system 16 via one-way check valve 110 .
[0060] Control 38 is adjusted to place saline syringe 20 in fluid connection with tubing 46 . Tubing 46 can, for example, terminate in a spike 48 or other connection member to cooperate with a septum 45 on source 40 (for example, a bottle) as known in the art. A small volume of saline is injected or expelled from saline syringe 20 to purge air from tubing 46 and spike 48 . Control 38 is then adjusted to place saline syringe 40 in fluid connection with dual check valve 50 . A small volume of saline is expelled to purge flush bypass line 120 of air. Dual check valve 50 provides sufficient resistance to flow such that saline expelled from saline syringe 20 passes through bypass line 120 rather than through dual check valve 50 .
[0061] Injector 70 is use to retract plunger 62 to draw saline from saline syringe 20 . injector 70 is then used to expel air in line between syringe 60 and catheter 100 by expelling (via advancement of plunger 62 ) the saline therefrom. At this point, all lines of system 14 are free of air and filled with saline. Syringe 60 is substantially empty except for a small amount of saline not expelled.
[0062] At this point, injector syringe 60 is preferably positioned within dose calibrating unit 200 or other radiation containment device in the case of injection of a radiopharmaceutical. Container 44 is opened and pharmaceutical source 40 is spiked to place source 40 in fluid connection with valve system 16 . Spiking of pharmaceutical source 40 can be done automatically, remotely or robotically to reduce or prevent exposure of operating personnel. The patient is then connected to patient fluid path set 80 via catheter 100 . System 10 is now ready for an injection. The pharmaceutical is drawn into syringe 60 by retraction of plunger 62 relative to syringe tip 64 and then injected into the patient by advancement of plunger 62 relative to syringe tip 64 . Saline is then expelled from saline syringe 20 , passing through bypass line 120 , to flush the pharmaceutical from patient fluid path set 80 . All of these functions are accomplished with little on no exposure of the operator or administering personnel to radiation.
[0063] In that regard, all adjustment of control 38 were made before the radiopharrnaceutical was drawn into fluid delivery set 15 . Control 38 can also be adjusted remotely or automatically (for example, via electronic/computer control) in, for example, cases when some pharmaceutical is within fluid delivery set 15 (for example, in a second or subsequent procedure in a case in which fluid delivery set 15 is used for multiple deliveries/injections) to prevent exposure of administering personnel. Other types of valve systems or assemblies, for example, a manifold system, can be used to effect the control of valve assembly 16 .
[0064] Fluid delivery set 15 is preferably disposable after one or more uses to, for example, reduce the risk of cross-contamination between patients. Fluid delivery set 15 , including valve system 16 , and/or other components of system 10 can be placed within a protective containment unit 18 during use thereof to further shield personnel from radiation that may emanate from, for example, valve system 15 . FIG. 1 B illustrates one embodiment of protective containment unit or shielded container 18 for fluid delivery set 15 of the present invention. In general, radioactive rays emanate in straight lines from a radiation source. Containment unit 18 provides a view of fluid delivery set 15 without providing a straight line of sight between the viewer and fluid delivery set 15 . In that regard, it is often desirable for administering personnel to have a view of tubing in a fluid path to, for example, provide visual assurance of the absence of air bubbles. Containment unit 18 includes a shielded housing 160 having a view port 162 . Radioactive frays cannot escape through view port 162 as there is no line of sight (that is, unobstructed line) between view port 162 and fluid delivery set 15 . Containment unit 18 includes a mirrored surface 164 to provide a view of fluid delivery set 15 . FIG. 1C illustrates another embodiment of a containment unit 18 a in which a view of fluid delivery set 15 is provided by mirrored surface 174 which is in alignment with fluid delivery set 15 via view port 172 . One or more additional mirrored surfaces 176 can be provided to give further views of fluid delivery set 15 .
[0065] In each of containment units 18 , one or more mirrored surfaces are used to provide a view of fluid delivery set 15 without creating an unshielded direct line between the viewer and the fluid delivery set 15 (or other radioactive source). There is no need to provide a transparent shield (for example, lead shielded glass) over view ports 162 or 172 because the lack of an unshielded direct line of sight between the viewer and fluid delivery set 15 prevents exposure to radiation. Elimination of leaded glass can be advantageous as such glass is often expensive and heavy and can sometimes diminish or degrade a view.
[0066] In the case of injection of a radiopharmaceutical, positioning a pressurizing unit or chamber such as syringe 60 within dose calibrating unit 200 such as the Capintec CRC-15PET dose calibrator available from Capintec, Inc. of Ramsey, N.J., which measures the total radiation of the volume of radiopharmaceutical enclosed within the pressurizing chamber, shields administering personnel from radiation and enables delivery of a known volume of the radiopharmaceutical having a known radiation level (as measured directly by dose calibrating unit 200 ). The accurate control of injection volume and flow rate provided by powered injector 70 enables automatic injection of a calculated volume of fluid (using for example processing unit 71 of injector 70 ) that will provide the level of radiation necessary, for example, for a PET or SPECT image given the measured radiation of the total volume of radiopharmaceutical contained within syringe 60 provided by dose calibration unit 200 . Thus, it is no longer necessary to calculate and wait for the precise moment in time when radioactive decay has brought the level of radiation of a volume of radiopharmaceutical to the desired level, thereby saving time, and reducing the complexity of the injection procedure.
[0067] FIGS. 2 - 4 C illustrate one embodiment of a setup for system 10 as described above. In this embodiment, a PULSAR injector available from Medrad, Inc. of Indianola, Pa. was used. Injection head 72 was separated from control unit 74 as described in U.S. Provisional Patent Application Serial No. 60/167,309, filed Nov. 24, 1999, U.S. patent application Ser. No. 09/721,427 filed Nov. 22, 2000 and U.S. patent application Ser. No. 09/826,430 filed Apr. 3, 2001, all assigned to Medrad, Inc. Injection head 72 is slidably positioned in general alignment with an opening 204 in dose calibration unit 200 on a generally vertical slide bar or stand 220 via a clamping extension 224 . Injector 70 also includes a first remote control unit 76 for communicating data/instructions such as injection volume and flow rate into control unit 74 remotely (via, far example, communication line 75 ). Further, injector 70 includes a second remote control unit 78 for remote manual control of drive member 79 of injector 70 . The function of first remote control unit 76 and second control unit 78 can be combined. On currently available PULSAR injectors, manual controls for drive member 79 are positioned upon injector head 72 . However, to prevent undesirable exposure to radiation in system 10 of the present invention, such controls are preferably also positioned remotely from injector head 72 . Saline source/syringe 40 can also be controlled via injector 70 through a second injector head (not shown) as described, for example, in U.S. Provisional Patent Application Serial No. 60/167,309, filed Nov. 24, 1999, U.S. patent application Ser. No. 09/721,427 filed Nov. 22, 2000 and U.S. patent application Ser. No. 09/826,430 filed Apr. 3, 2001.
[0068] In the embodiment of FIGS. 2A through 4C, system 10 is positioned upon a cabinet stand 300 . Slide bar 220 extends generally vertically from cabinet stand 300 . Cabinet stand 300 includes a passage 310 farmed therein through which syringe 60 can pass to enter dose calibration unit 200 . Cabinet stand 300 also preferably includes a second passage 320 through which pharmaceutical source 40 can pass to be deposited with container 44 . A cap 330 can be provided to seal container 44 . In the embodiment of FIGS. 2A through 4C, first passage 310 is preferably oriented such that radiation emanating therefrom is directed generally vertically toward the ceiling (or in another suitable direction) to reduce the likelihood that personnel within the room of the injection procedure will be exposed to such radiation.
[0069] Injector head 72 is oriented in a generally vertical, downward direction on slide bar 220 to position syringe 60 within dose calibrating unit 200 . To ensure that air is purged from a syringe, however, injector heads are typically positioned such that the exit or syringe tip of the syringe if oriented upward during purging. As air is less dense than other injection media and saline flushes, the air rises to the syringe tip or exit and is readily purged by, for example, forcing a small amount of fluid from the syringe. To enable a generally vertical orientation of syringe 60 with syringe tip 64 oriented upward in the present invention, a syringe adapter 400 was used.
[0070] Syringe adapter 400 attaches to injector 70 in preferably the same manner as syringes are attached thereto. Attachment adapters can be used as known in the art to facilitate such attachment. Adapter 400 can, for example, be removably attached to injector 70 via flanges 412 on an attachment member 410 that cooperate with retaining slots in injector 70 (not shown) as described in U.S. Pat. No. 5,383,858, assigned to the assignee of the present invention, the disclosure of which is incorporated herein by reference.
[0071] Adapter 400 includes a drive extension 420 that removably connects to drive member 79 of injector 70 via an attachment member 430 that can, for example, include capture members that cooperate with a drive member flange 79 . Drive extension 420 attaches to a syringe carriage 440 at an upper plate member 442 of syringe carriage 440 . Syringe carriage 440 is slidable disposed upon adapter 400 via slide bars 450 a and 450 b that extend from the rear surface of attachment member 410 to a fixed, lower base 460 . Syringe carriage 440 includes a syringe attachment member 444 attached to a lower plate member 446 of syringe carriage 440 . Upper plate member 442 and lower plate member 446 are connected via connecting members 448 (for example, metal or plastic bars), Syringe attachment member 444 can include slots (not shown) that cooperate with flanges 66 on a rear portion of syringe 60 to removably attach syringe 60 to syringe carriage 444 as illustrated in FIGS. 4 A, and 4 C (as described, far example, in U.S. Pat. No. 5,383,858). Via syringe carriage 440 , the barrel of syringe 60 is slidable in an upward and downward direction on adapter 400 .
[0072] Adapter 400 further includes a plunger extension 470 that includes a plunger attachment including, for example, a flange 474 that cooperates with capture members 63 on the rear of plunger 62 to removably connect plunger extension 470 to plunger 62 . Adapters as known in the art can facilitate connection of plunger extension 470 to various plungers. Plunger extension 470 maintains plunger 62 in a fixed position relative to base 460 and injector head 72 . By upward and downward movement of syringe carriage 440 (via injector drive member 79 and drive extension 420 ), the position of plunger 62 within syringe 60 is changed. For example, advancing drive member 79 causes the barrel of syringe 60 to move downward and causes a corresponding or relative advancement of plunger 62 toward syringe tip 64 , thereby causing fluid to be expelled from syringe 60 . Upward movement (or retraction) of drive member 79 causes the barrel of syringe 60 to move upward and corresponds to retraction of plunger 62 relative to syringe tip 64 , thereby drawing fluid into syringe 60 .
[0073] An extending syringe adapter such as adapter 400 , enables use of commercially available injector systems and commercially available dose calibrators in the system of the present invention without substantial modification. The use of adapter 400 is transparent to the injector control software/hardware as no change and/or recalibration of the controlled movement of drive member 79 of injector 70 is required.
[0074] [0074]FIGS. 5A Through 5D illustrate several other embodiments of the present invention for providing dose calibration generally in real time. In FIG. 5A, a pressurizing device 520 (for example, a syringe in communication with a powered injector) and a radiopharmaceutical source 540 are positioned within a dose calibrator 550 . In FIG. 5B, radiopharmaceutical source 540 is placed in a dose calibrator 550 ′, while pressurizing device 520 is placed in a shielded enclosure 560 . In the embodiment of FIGS. 5C and 5D, radiation level detectors are placed in operative connection with flow lines (for example, tubing). In FIG. 5C, a radiation detector 570 is placed in line between radiopharmaceutical source 540 (enclosed within a shielded container 580 ) and pressurizing device 520 (enclosed within a shielded container 590 ). In FIG. 5D, a radiation detector 570 ′ is placed in line with the exit of pressurizing device 540 . In general, the flow rate through the line in operative connection with radiation detector 570 or 570 ′ is known. The radiation level of a particular dose is thus easily measured using radiation detectors 570 and/or 570 ′.
[0075] Although the present invention has been described in detail in connection with the above examples, it is to be understood that such detail is solely for that purpose and that variations can be made by those skilled in the art without departing from the spirit of the invention except as it may be limited by the following claims.
|
A method and apparatus of dispensing a radiopharmaceutical wherein a source of flushing fluid is connected to a first port of a fluid delivery set; a pressurizing unit of a powered injector system (including a powered injector and the pressurizing unit) is connected to a second port of the fluid delivery set; air is purged from the fluid delivery set; and, after purging air from the fluid delivery set, a third port of the fluid delivery set is connected to a source of the radiopharmaceutical. A valve system is included to control flow of fluid. A syringe is operatively connected with a powered injector. A radioactive shield encloses the syringe during operation to protect personnel from detrimental effects. A dose calibrator measure the radioactivity in the syringe.
| 0
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the US National Stage of International Application No. PCT/EP2007/062481 filed Nov. 19, 2007 and claims the benefit thereof. The International Application claims the benefit of German Patent Application No. 10 2006 055 157.5 DE filed Nov. 22, 2006, both of the applications are incorporated by reference herein in their entirety.
FIELD OF INVENTION
[0002] The invention relates to an optical measuring cell and a gas monitor for gas absorption methods, and a gas monitor.
BACKGROUND OF INVENTION
[0003] In the fields of photometry and optical spectroscopy to determine the concentration of a gas component in a test gas by means of absorption measurement, the problem arises with the measuring sample cell that the transmission of the empty sample cell without any target gas present, and therefore without any absorption due to the target gas, must be known in order to be able to identify the target gas by evaluating the gas-dependent absorption.
[0004] A known solution consists in flushing the sample cell with a gas from a reservoir, for example a compressed gas bottle, which does not contain the gas components to be measured and also does not absorb in the wavelength region being used. Nitrogen, for example, is usable for this purpose if ambient air is used as the test gas. Since conventional measuring cells usually have large volumes, depending on their application, being typically >100 cm 3 to several liters, and a flushing gas volume which is a multiple of the measuring cell volume is needed for each flushing operation, then for continuously running or large numbers of measuring processes, this results in a substantial consumption of gas.
SUMMARY OF INVENTION
[0005] It is an object of the invention, in order to provide a stable calibration level for an optical gas sensor system with, for example, pre-determined wavelengths and a non-scanning system, to describe a measuring path which is independent of changes/soiling in the optical measuring system or the measuring sample cell and which is characterized by having the smallest possible test gas volume.
[0006] The solution is provided by an optical measuring cell and a gas monitor as claimed in the independent claims.
[0007] Advantageous embodiments are contained in the dependent claims.
[0008] In order to measure the gas-dependent absorption, at least one hollow fiber is used, having a diameter typically in the sub-millimeter region. Both the gas being tested and the light used for the absorption measurement are fed into the core of the hollow fiber which is open at the front face. Coupling in of the light takes place in the longitudinal direction of the hollow fiber. Due to the oblique reflection angles occurring therein, even with the hollow fiber, particularly a glass fiber, tightly bent, the light can be guided for several meters without significant loss.
[0009] Using hollow fibers, the particular advantage of a long absorption path is obtained, coupled with a sensitive detection of gas, as well as small measuring cell volumes. For example, a meter length of a hollow fiber with a diameter of 0.5 mm has a volume of approximately 0.2 cm 3 . Therefore only a few cm 3 of flushing gas is required to flush such a fiber. A 3-liter bottle of flushing gas with a pressure of 200 bar used for repetitive measurements on a 10-minute cycle and with a gas consumption of approximately 1 cm 3 per flush would be able to supply the measuring apparatus with flushing gas for over ten years. A self-sufficient measuring apparatus can therefore be realized which could last for all its service lifetime without replenishment of consumable media, for example, for flushing.
[0010] It is advantageous to replace the flushing gas supply B, comprising a reservoir B 2 such as a compressed gas bottle, by a flushing gas generator B 1 wherein the flushing gas is directly generated in a cleaning procedure. Theoretically, the design then consists of the optical measuring cell 14 and the flushing gas generator B 1 , which itself essentially consists of a gas supply pump 10 and a gas filter 11 .
[0011] The invention consists essentially in the combination of the use of a hollow fiber with its typical volume as the optical measuring cell. This depends on the fiber length and is usually in the range of less than or equal to 1 cm 3 per meter of fiber length, as a result of which low demands are made on the quantity of flushing gas required when totaled over many flushing cycles. The demands made on the flushing gas supply can be met with gas bottles or flushing gas generators of small volume capacity, as described above.
[0012] Where gas measurements are made over a long period of time, the advantage arises that for a considerable period, no refilling of the supply of auxiliary gas/flushing gas for the measuring apparatus is necessary where a compressed gas bottle is used for supplying flushing gas. This results in the possibility of providing self-sufficient gas monitors which require minimal maintenance with regard to the auxiliary gas. Due to the compact components, such as hollow fiber and flushing gas generator, highly sensitive portable gas monitors can also be realized using this measuring principle.
BRIEF DESCRIPTION OF THE DRAWING
[0013] The invention will now be described with the aid of non-restrictive exemplary embodiments, making reference to the accompanying drawing:
[0014] FIGURE shows a measuring cell.
DETAILED DESCRIPTION OF INVENTION
[0015] The FIGURE shows a measuring cell with a gas supply A, comprising an optical measuring cell 14 with a hollow fiber 1 .
[0016] The FIGURE shows an exemplary embodiment of the invention in detail. The arrangement comprises the optical measuring cell 14 , the test gas delivery system and the flushing gas delivery system as well as a flushing gas supply. The optical measuring cell comprises the hollow fiber 1 as the absorption measuring cell with the light source 2 , the light detector 3 and the control and evaluation circuit 4 .
[0017] The test gas delivery system comprises the test gas suction tube 5 , optional fine-pored particle filters 6 and, following the hollow fiber 1 , a valve 7 before the test gas delivery pump 9 , as well as a gas outlet. A valve 8 closes off the measuring cell with the gas delivery A in the direction toward the flushing gas supply B. The flushing gas supply can comprise a compressed flushing gas bottle B 2 . However, the use of a flushing gas supply using a flushing gas generator B 1 which generates a flushing gas and which contains none of the gas to be detected during measuring is advantageous. The flushing gas generator B 1 comprises the gas delivery pump 10 and the actual gas generator. Alternatively, the flushing gas generator comprises a flushing gas reservoir, for example, a pressurized gas bottle 12 with the regulating valve 13 for setting the gas flow.
[0018] Sequence of the Measuring Cycle:
Flushing cycle: the flushing gas pump 10 is in operation and the valve 8 is opened, whilst the valve 7 is closed. The test gas delivery pump 9 is switched off. The flushing gas flows through the hollow fiber 1 and flushes the test gas residue back into the test gas atmosphere 15 . Following a sufficient flushing time, an optical absorption measurement is carried out, initially the calibration measurement, which is performed with a volume of flushing gas in the hollow fiber. Measuring cycle: the valve 8 is closed, the valve 7 is opened, the flushing gas pump 10 is switched off and the test gas pump 9 is put into operation. Now the test gas flows through the hollow fiber 1 and an optical transmission measurement is carried out. The ratio of the transmission with test gas to that with flushing gas (calibration measurement) gives the gas-dependent transmission, dependent on the fundamental transmission of the absorption path, the hollow fiber. The procedure is similar when the flushing gas is provided from a compressed gas bottle 12 .
[0021] In the exemplary embodiment, test gas and flushing gas flow through the measuring fiber in contrary directions. By reversing the delivery direction of the test gas delivery pump, it is possible to have both gases flow through the hollow fiber in the same direction.
[0022] Example for Flushing Gas Generators:
[0023] 1. If the gas concentration measurement takes place, for example, in a hydrogen atmosphere, the gas filter is a heated palladium membrane, which is comparable with a Pd diffusion cell. The required pressure difference is provided by a gas delivery pump. The contaminated hydrogen is fed to the filter. Since only protons can diffuse through Pd, on the secondary side pure hydrogen, which can be used as the flushing gas, is produced.
[0024] 2. If the measurement takes place in air or in an oxygen atmosphere, a pump cell which conducts oxygen ions, such as zirconium oxide at 600° C., suggests itself as the oxygen supplier. A voltage is applied across the primary side and the secondary side of the heated zirconium ceramic material, which leads to oxygen transport through the ceramic material. On the secondary side pure oxygen, which can be used as the flushing gas, is produced. No extra pump is required with this embodiment, since the pump action is contained in the principle of the cell. According to this principle, the reference gas oxygen can also be generated through the electrochemical decomposition of other oxygen-containing gases, such as H 2 O, CO 2 , CO, NO, NO 2 .
[0025] 3. Oxygen or hydrogen can be produced in the liquid phase by electrolysis of acidified water. Depending on the gas required, the gas produced either at the cathode or the anode can be used for flushing. The electrolysis is only started when flushing gas is needed. An electrolysis cell and possibly a gas delivery pump are required. A unit of this type can be operated over several years if only the aforementioned small quantities of flushing gas are needed.
[0026] 4. The small quantities of flushing gas needed for the flushing process can be produced in the required quantity and purity by known chemical reactions. Examples of such methods for the production of flushing gases are:
[0027] 4a. Production of Hydrogen:
[0000] Dissolving aluminum or silicon in a concentrated alkali solution
[0000] Al+NaOH+3H 2 O→Na[Al(OH) 4 ]+3/2H 2
[0000] The reaction is started by adding the Al to the sodium hydroxide solution. Once a sufficient quantity of gas has been generated, the feeding in of Al is stopped. The apparatus consists of respective supply containers for the NaOH and the Al in the form, for example, of filings, a dosing apparatus for the aluminum filings and a gas delivery pump. Depending on the chemical supplies and the number of flushing cycles, the apparatus can supply flushing gas for several years.
[0028] 4b. Production of Nitrogen:
[0000] Air is passed over glowing copper, by means of which the oxygen can be entirely removed. What remains is a mixture of nitrogen with 1% argon (which has no interfering effect). Apart from the Cu and the heater for the Cu, a gas delivery pump is also required. The procedure is only started when the measuring cell is to be flushed. Maintenance is required essentially only to replace the copper. Depending on the number of flushing cycles and the gas quantity needed, the apparatus can be used for several years without maintenance.
[0029] 4c. Production of Oxygen:
[0000] Oxygen can be produced in precisely calculable quantities by dropwise addition of potassium permanganate solution to a solution of hydrogen peroxide acidified with sulfuric acid. Two supply containers are needed for the chemicals, which are dosed into a reaction vessel, and a gas delivery pump. The procedure can take place as follows:
[0030] When flushing is to be started, a volume of hydrogen peroxide corresponding to the desired oxygen quantity is placed in the reaction vessel and the potassium permanganate is added dropwise.
[0031] An alternative method of producing oxygen is the decomposition of potassium chlorate or potassium permanganate by heating. At the start of the flushing procedure, the chemical is heated for long enough until a sufficient quantity of the gas has been generated. Then the process is stopped by cooling. Only the supply vessel, possibly a reaction vessel, a dosing device for the chemicals and a gas delivery pump are required. Only the supply of chemicals has to be topped up, their quantity determining the maintenance time intervals.
[0032] 5. Cleaning air with adsorption traps for water and carbon dioxide: water vapor can be removed from the air stream by passing the air through desiccants (silica gel or CaCl 2 ). CO 2 can be removed from the air by reaction with CaO. Only the chemical containers and a gas delivery pump are needed. The apparatus for drying the gas can be regenerated by simple heating, whilst the CaO is consumed and must be topped up. The maintenance interval depends on the size of the chemical supplies and the flushing gas requirement.
[0033] Due to the low volume of the measuring cell and the small quantity of flushing gas as a consequence of the use of a hollow fiber as the optical measuring cell, the flushing gas generator can also be made compact. This enables the realization of gas monitors in a compact form, since not only the gas absorption measuring cell, but also the flushing gas supply, can be constructed small.
|
An optical measuring cell for measuring gas absorption with a light source for introducing light into a measuring volume and a light sensor located approximately opposite the light source in the direction of light propagation and relative to the measuring volume for receiving light that is guided through the measuring volume is provided. The concentration of one or multiple target gases in the measuring volume is detected by an evaluation unit. The measuring volume is constituted by an internal volume of a hollow fiber having an internal diameter less than 1 mm.
| 6
|
BRIEF SUMMARY OF THE INVENTION
This pump is intended as a replacement pump for use on oil burners. Some oil burner drive shafts rotate counterclockwise and some clockwise. It has therefore been necessary for a manufacturer of replacement pumps to stock one line of pumps adapted for one direction of rotation and another line of pumps adapted for the opposite direction. Attempts have been made to solve this problem by providing pump units which, by disassembly and reassembly, could be made to pump fluid in the same direction regardless of the direction of rotation of the pump.
Ths pump of the present invention, when assembled for one direction of rotation, may be adpated for the opposite direction by removing a single plate and the bolts holding it in place, turning the plate over and replacing it and the bolts. No other part of the pump has to be removed or disassembled.
DRAWINGS
FIG. 1 is a cross-sectional view of a pump assembly embodying the invention, taken on the line 1--1 of FIG. 2.
FIG. 2 is a cross-sectional view of a pump taken on the line 2--2 of FIG. 1.
FIG. 3 is a sectional view, taken on the line 3--3 of FIG. 1, with the pump set for one direction of rotation of the shaft.
FIG. 4 is a view similar to FIG. 3 with the pump set for rotation of the drive shaft in the opposite direction.
FIG. 5 is an exploded view of the rotary pump, per se.
FIG. 6 is a view of the end plate shown in FIG. 5, but in the reverse position.
DETAILED DESCRIPTION
FIG. 1 illustrates a complete pump assembly including a housing 1 having a surface 1a adapted for mounting against a pad on an oil burner. A shaft 2 extends into the housing 1 and is provided at its end with suitable coupling means, such as flats 2a for engaging mating coupling means on a motor driven shaft in the oil burner. A cover plate 3 closes the outer end of the casing 1. The casing 1 and cover plate 3 define a chamber 4 connected to an inlet 5 and normally filled with the oil or other fluid to be pumped. A pressure regulating valve 6, of conventional construction, is located in another chamber in the pump housing 1, and delivers the fluid being pumped through a discharge conduit 7 at substantially constant pressure. A gear pump assembly is generally indicated at 11, and includes a base 12, and ring 13 encircling a pump rotor 14 and its cooperating gear 15 which is attached to the shaft 2. A fixed plate 16 has a crescent 16e attached to its face nearest the base 12. The crescent 16e fits between the rotor 14 and the gear 15. A reversible plate 17 is mounted on the opposite side of the fixed plate 16. The reversible plate is held in place by three bolts 18, which extend through the fixed plate 16, the ring 13 and the base 12 and are threaded into the housing 1.
Two additional bolts 21 extend through the fixed plate 16, the ring 13 and the base 12 into the housing 1. A screen 22 of conventional form, encircles the pump assembly 11.
The base 12 has five holes 12a for receiving the bolts 18 and 21, and an outlet passage secton 12b. The ring 13 has five holes 13a for receiving the bolts 18 and 21 and an outlet passage section 13b aligned with the outlet passage section 12b.
The fixed plate 16 has five holes 16a for receiving the bolts 18 and 21, and an outlet passage section 16b aligned with the outlet passage section 12b and 13b, and two reversible flow passages 16c, which are aligned with the points of intake and discharge of the pump rotor 14. The point where the teeth of gear 15 mesh with the teeth of the rotor 14 is always the point of discharge, and the point where the teeth of gear 15 separate from the teeth 14 is always the point of intake. These two points always have the same two locations, but their functions are interchanged when the direction of rotation of the rotor is reversed.
Reversible plate 17 is provided with three holes 17a for receiving the bolts 18, and an inlet port 17b which extends completely through the plate. With the parts aligned as shown in FIG. 5, port 17b provides communciation between the interior of the chamber 4 and the right-hand one of the two reversible flow passages 16c. On its outer surface, as viewed in FIG. 5, the plate 17 is provided with a recess 17c, shown as a groove. On its inner surface, best seen turned outward in FIG. 6, the plate 17 is provided with a recess 17d, shown as a groove. When the plate 17 is assembled with the plate 16 in the orientation shown in FIGS. 3 and 5, the recess 17d provides communication between the left-hand one of the reversible passage sections 16c and the outlet passage section 16b, and the pump is adapted for counter-clockwise rotation of the shaft 2, as illustrated.
The inlet passage to the pump may be traced through the inlet port 17b and the right-hand one of the reversible passages 16c to the point where the gear 15 is separating from the teeth of the rotor 14, which is then the intake point of the pump. The left-hand one of the reversible passages 16c is then aligned with the point where the teeth of gear 15 mesh with the teeth of the rotor 14, which is then the discharge point of the pump. The path of flow of fluid discharged from the pump extends through the left-hand one of the reversible passages 16c through the recess 17d to the outlet passage section 16b and then through the outlet passage sections 13b and 12b, and thence through a suitable passage 25 (FIG. 2) to the pressure regulating valve 6 and the discharge conduit 7.
When it is desired to reverse the direction of rotation of the shaft 2, a direction of flow between the inlet 5 and outlet conduit 7 may be maintained the same simply by removing the bolts 18, turning the plate 17 over, so that the surface viewed at the right-hand end in FIG. 5 is against the fixed plate 16, and replacing the bolts 18. The inlet passage to the pump is then through the inlet port 17b in the location shown in FIG. 6 and thence through the left-hand one of the reversible passages 16c to the intake point where the gears 14 and 15 are separating which is now to the left of the point where gears mesh. The outlet conduit from the pump now extends from the discharge point, i.e., the meshing point of the gears, through the righthand one of the passages 16c and the recess 17c and thence into the outlet passage sections 16b, 13b and 12b, to the passage 25.
It may be seen that the entire pump unit, as viewed in FIG. 1, may be packaged and carried as a single portable unit, and that the direction of rotation of the shaft may be reversed while maintaining the direction of flow the same simply by reversing the plate 17. This is accomplished by taking out three bolts 18, leaving the other parts of the pump assembly held firmly together by two bolts 21. The plate is then turned over and replaced to the plate assembly by means of the same bolts 18.
When the plate 17 is turned over, it is rotated about an axis extending vertically through the middle one of the holes 17a, and contained in a plane extending diametrically through the pump. The inlet port 17b and the inlet ends of the recesses 17c and 17d are located symmetrically with respect to that axis about which the plate is rotated. In other words, the inlet port 17b is a certain distance to one side of that axis and the inlet ends of both recesses 17c and 17d are the same distance to the opposite side of the same axis. The two reversible flow passages 16c in the fixed plate 16 are also symmetrically located with respect to the diametrical plane containing that axis, so that in either position of the plate 17, the inlet port 17b is aligned with one of the passages 16c, and the inlet end of one of the recesses 17c and 17d is aligned with the other one of the two passages 16c.
The fixed plate has a circular contour. The plate 17 is a segment of a circle somewhat greater than a semicircle. By so constructing the plate 17, the bolts 21, which remain in the pump when the plate 17 is removed, prevent the plate from being assembled in any wrong orientation. In other words, after the plate 17 has been removed and rotated about the vertical axis through the middle hole 17a, there is only one orientation in which it can be reassembled with the pump without interfering with the heads of the two remaining bolts 21.
The pump illustrated is intended for submerged operation. In other words, it is enclosed in the chamber 4 which is filled with the fluid to be pumped. Under these circumstances, the pump inlet conduit is simply the port 17b and the aligned passage 16c. The apparatus of the invention might be used in other installations where the pump is not submerged, in which case an external inlet conduit could be attached to the port 17b, which could be threaded to receive a fitting forming part of the conduit.
While the invention is illustrated as applied to a gear pump of the fixed crescent type, including an externally toothed gear cooperating with a larger internal toothed gear, it is equally applicable to pumps of other types, including, for example, gear pumps in which both gears have external teeth and rotary sliding vane type pumps.
While the outlet passage arrangement shown, including the sections 12b and 13b, has many advantages, for example, the advantage of simplicity, it should be understood that other outlet passage arrangements may come within the broader aspects of my invention.
|
This pump is driven by a shaft which may rotate in either direction. The direction of flow of fluid at the inlet and outlet ports of the pump may be maintained the same regardless of the direction of rotation. When the pump is set for one direction of rotation, it may be adapted for use with the other direction of rotation by removing a single plate, turning the plate over, and replacing it. The plate is held by bolts whose removal does not cause disassembly of any other parts.
| 5
|
This application claims the benefit of U.S. Provisional Application No. 60/076,333, filed Feb. 27, 1998, entitled "Flexible Inorganic Electrolyte Fuel Cell Design", by Ketcham et al.
FIELD OF THE INVENTION
The invention is a fuel cell using an inorganic electrolyte membrane, useful for power generation, particularly for use in transportation, more particularly, high temperature fuel cells using liquid fuel (diesel and gasoline) for automobile power plants and intermittent operation power plants. In particular, the inventive fuel cell is designed to have non-planar electrolyte/electrode structures that are mechanical and thermal shock resistant.
BACKGROUND OF THE INVENTION
Polymer electrolyte fuel cells that utilize hydrogen are well known and have been proposed for use as energy sources in automobiles. As these cells can only consume hydrogen, to utilize liquid fuels, reforming of the fuel to hydrogen and carbon monoxide/dioxide and oxidation or scrubbing of the carbon monoxide, which poisons the system at very low levels, is required.
Solid oxide fuel cells are well known, but have been limited to power sources that are not temperature cycled repeatedly. To be useful for an automotive power plant, a fuel cell needs to become operational quite fast, preferably faster than 5 minutes, more preferably less than two minutes and even more preferably less than 30 seconds. Energy requirements to keep a high temperature solid oxide type fuel cell hot all the time in an auto are prohibitive. Hence, as fuel cell would need to be heated almost every time an auto was used, the cell would need to withstand perhaps as many as 10 to 20 thousand heating cycles. Until now no inorganic electrolyte solid oxide fuel cell has been designed having sufficient thermal shock and thermal cycling resistance to be considered for this application.
Flexible thin ceramics have been described for example in co-assigned U.S. Pat. No. 5,089,455, some compositions of which would be useful electrolytes for fuel cells. Recently, U.S. Pat. No. 5,273,837 has described the use of such compositions to form a thermal shock resistant fuel cell. Nowhere in these documents is the application of these compositions and these fuel cells for automotive power plants mentioned. Thin corrugated ceramic structures have been disclosed as fluid heaters in U.S. Pat. No. 5,519,191.
The foregoing discussion is intended to show use of zirconia as an electrolyte is known, and use of ((LaSr)MnO 3 ) and other expansion matched electrically conducting perovskite structures are known for use as air side electrodes, as well as use of zirconia/nickel composites for fuel side electrodes. In addition, metals, intermetallics and LaCrO 3 have been used for interconnect structures. Notwithstanding, there continues to be a need for improved solid oxide fuel cells, particularly fuel cells capable of withstanding very high heating and/or thermal cycles. This is the focus of the present invention.
SUMMARY OF THE INVENTION
Briefly, the invention relates to a solid electrolyte fuel cell having an oxidant reservoir, a fuel reservoir, and an electrolyte structure interposed between the oxidant and fuel reservoir, in which the electrolyte is of non-planar sheet structure.
In one aspect, the invention relates to a solid electrolyte fuel cell in which the electrolyte is a non-planar structure of a thin, flexible, pre-sintered, polycrystalline ceramic sheet. The boundary shape of the curved electrolyte sheet is not critical and may be circular, oval, elliptical, pentagonal, hexagonal, heptagonal, octagonal or the like.
In another aspect, the solid electrolyte fuel cell is of a central feed design.
In a further aspect, the invention relates to a thermal shock resistant solid electrolyte fuel cell for repeated and intermittent on/off use, capable of withstanding 100 to 4,000 thermal cycles of from room temperature to operating temperature of up to 1000° C. in times ranging from less than five minutes to one hour.
In still another aspect, the invention relates to a solid electrolyte fuel cell capable of withstanding up to 4,000 thermal cycles of from room temperature to operating temperatures of up to 1000° C.
As used in this specification:
"heating cycle" means that the fuel cell is repeatedly and/or intermittently heated from room temperature or any beginning temperature, to an operating temperature of up to 800, 1000° C. or even higher, and then cooled back to room temperature or beginning temperature.
"non-planar" means that the electrolyte structure does not lie in a plane.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1. is a side feed, radial flow fuel cell design.
FIGS. 2 and 3 represent a center feed, radial flow fuel cell design showing a unit cell of a stack.
FIG. 4 is a schematic exploded view of a centrally internally manifolded solid oxide fuel cell (SOFC) stack "repeat unit" showing use of nested manifold tubes with perforated ceramic rings for gas delivery to electrodes, and baffles to prevent fuel/air mixing.
FIG. 5 is a cross-section view of the repeat unit of FIG. 4 showing delivery of fuel and air, and use of fibrous mats as current collectors
FIG. 6 is an exploded view of a repeat unit showing use of porous and non-porous spacers to separate layers and deliver fuel and air.
FIG. 7 is a cross-sectional view of the repeat unit of FIG. 6 showing use of porous and non-porous spacers to separate layers and deliver fuel and air, and use of fibrous mats as current collectors.
DETAILED DESCRIPTION OF THE INVENTION
The invention is an inorganic electrolyte fuel cell for electrical power, particularly powering automobiles, trucks, buses, locomotives, ships, etc. The fuel cell is a thermal shock and thermal cycling resistant inorganic electrolyte fuel cell that can be heated to operating temperature rapidly and survive many thousands of heating cycles. In addition, the inventive fuel cell can use liquid fuels such as diesel, gasoline, ethanol and methanol and the like. In another aspect, the invention relates to a fuel cell design, particularly a non-planar electrolyte design, for such a fuel cell. Advantages of such a fuel cell for transportation power include better fuel efficiency (better gas mileage), lower polluting emissions, lighter weight, no vibration, less friction and wear, less raw materials and due to the flexible ceramic foil design, ease of manufacturing.
The inventive fuel cell consists of manifold structures which are capable of reducing or limiting thermal stress on the cell components. The essential components of these structures are: 1) a flexible non-planar electrolyte sub-assembly; 2) fuel and oxidizer manifolding tubes, some of which may be porous and/or perforated; and 3) an optional electrically conductive current collector grid, mesh, felt or fiber mat composed of metal, cermet, metal coated ceramic or conducting ceramic.
A key aspect of the inventive fuel cell is that the cross-sections of the manifolding tubes are chosen so as to reduce the stress and limit the likelihood of crack initiation and propagation. The manifolding tubes may be cylindrical in nature, or of circular or elliptical cross-sections. Preferably, the manifolding tubes are circular and/or possess rounded features with no sharp edges. For example, the tubes may have square cross-sections but with rounded corners. Manifolding tubes with sharp corners are problematic because the sharp corners tend to act as stress concentrators during thermal cycling.
Another key aspect of the invention is the use of a non-planar, e.g., conical or smoothly curved, electrolyte sheet structure. The electrolyte sheet itself will have a non-planar shape that incorporates at least one stress relief region elevated above a sheet base plane. For the purpose of the present description we define the sheet base plane as a reference plane generally parallel with the sheet and containing the straight baseline spanning the largest linear dimension of the sheet. For adequate stress relief, the elevation of the sheet portion(s) above the sheet base plane should be such that the ratio of sheet elevation to largest sheet dimension is at least about 1:600, but no more than about 1:3. Preferably, this ratio will be no more than about 1:6. Flexible sub-assemblies consisting of intimately bonded anode/electrolyte/cathode sandwiches, such as described in U.S. Pat. No. 5,089,455 but with appropriately added curvature, are preferred. The sub-assemblies may also possess integral current collectors in the form of grids, or lines or porous conductive layers.
Preferably the electrolyte is chosen from ionic conductors such as yttria doped zirconia, calcia doped zirconia, rare earth oxides doped with aliovalient oxides such as: ceria doped with yttria and/or gadolinia and or ytterbia, and or erbia and other trivalent oxides, particularly other rare earths; trivalent rare earth oxides such as yttria, gadolinia, neodymia, ytterbia doped with aliovalient oxides such as magnesia, calcia, strontia and other +2 valence metal oxides and mixed rare earth gallates and aluminates such as lanthanum aluminate, and lanthanum gallate or neodynium aluminate and gallate doped with aliovalient oxides such as magnesia, calcia and other +2 valence metal oxides. The anode and cathode integral layers provide electrical contact, and three phase boundaries (gas/electrolyte/catalyst particle), on the surface of the electrolyte for the appropriate electrochemical reactions to occur.
In one particularly useful embodiment, a manifolded fuel cell with improved resistance to thermal or mechanical stress during operation is produced using circular flexible sub-assemblies. Unlike other manifold designs which tend to restrict the bending of the anode/electrolyte/cathode sub-assemblies, the present design allows the sub-assemblies to bend or flex to relieve stress. This is especially significant in the case of stress due to thermal gradients. Such stresses can be alleviated through buckling of the sub-assemblies. The buckling reduces the total stress in the sub-assembly, and therefore reduces the chance of breakage.
It is preferred that the manifolding tubes or, the tube in contact with the electrolyte, be of a material, which is closely matched in expansion to the electrolyte, and/or which is compliant due to the porous or perforated structure which the manifolding tubes possess. Corrugations of the electrolyte may also be made in the manifold or other tube contact areas for greater compliance. For zirconia-based electrolytes, such manifold materials may include, but are not restricted to, zirconia, zirconia-titania alloys, glass-ceramics in the alkali-rare earth-silicate family, glass-ceramics in the alkali-rare earth-silicate family, nickel and nickel-zirconia cermets, stainless steels (especially those in the ANSI 400 series), nickel alloys, and the like. If desired, one means of producing porosity in these materials is through partial sintering of powder compacts of these materials.
The means of collecting the current from the anode or cathode (the current collector) may be an integral part of the sub-assembly. The current collector may also employ a separate non-integral conductive wool, felt, or fibrous mat. If a relatively thick (>100 micron) current collector is employed, it should be of a compliant material so that the sub-assembly is able to bend to relieve stress.
The current collector should be chosen so that it is compatible with the oxidizing or reducing nature of the fuel cell environment. Current collector elements in contact with the cathode should include a conductor which is stable in an oxidizing environment. Examples of such conductors are noble metals, including silver, gold, platinum, palladium, as well as alloys and cermets of these. Other useful materials for the current collector include, oxidation resistant metals such as certain nickel alloys, conducting ceramics such as doped rare-earth oxides of chromium, manganese, cobalt, nickel, and the like, and doped zirconias, such as copper and titanium doped zirconium oxide.
Current collector elements in contact with fuel are chosen from conductors which are stable in reducing environments such as conducting metals including nickel, nickel cermets, such as nickel-zirconia cermets, ferrous alloys, chrome alloys, and the like, conducting ceramics such as doped rare-earth oxides of chromium, manganese, cobalt, nickel, and the like, as well as doped zirconias, such as copper and titanium doped zirconium oxide.
The manifold may be prepared so that adjacent sub-assemblies possess one of two possible relative orientations. In one of these the adjacent sub-assemblies are similarly oriented so that the anode of one sub-assembly is adjacent to the cathode of the next nearest sub-assembly (anode/electrolyte/cathode--anode/electrolyte/cathode). This first orientation can be referred to as a "A/E/C-A/E/C" repeating manifold in that the adjacent sub-assemblies repeat Anode/Electrolyte/Cathode in the same orientation. In this orientation adjacent cells can easily be connected electrically in series by connecting the cathode of one sub-assembly to the anode of the adjacent sub-assembly. Such an arrangement is similar to a battery in that the voltage across the total assembly is the sum of the voltages of all of the sub-assemblies. In the A/E/C-A/E/C repeating orientation, a non-porous metal or ceramic interconnect, or separator disk is required between each sub-assembly to separate the fuel which is in contact with the anodes from the oxidizer which is in contact with the cathode. The repeat unit of such a fuel cell generator can then be separator/current collector with manifolding tube section(s)/anode/electrolyte/cathode/current collector with manifolding tube section(s). This basic unit is repeated to form the manifold.
The current collector, if it consists of a wool or fibrous mat, may serve to allow the diffusion of the gases from the manifolding tube sections to each electrode. If the separator is electrically conducting then, when in operation, a complete circuit is made from the anode of one cell, through the electrolyte, the cathode, one current collector, the separator, and another current collector, to the anode of the adjacent cell. If the separator is not electrically conducting, then a separate means must be provided for completing the electrical circuit. If a separate means is provided for completing the circuit, then the assemblies may be connected either in series or in parallel.
In a second orientation, adjacent sub-assemblies are oriented in the opposite fashion so that the anode of one sub-assembly is adjacent to the anode of the next nearest sub-assembly, A/E/C-C/E/A (anode/electrolyte/cathode--cathode/electrolyte/anode). In the A/E/C-C/E/A manifold the separators are optional since this design does not require separation of the fuel and oxidizer between the adjacent sub-assemblies. The A/E/C-C/E/A design does require electrical isolation between the adjacent anodes or cathodes. This can be accomplished by a non-conducting separator or a non-conducting compliant porous layer, mat, or felt. In this manifold design a separate means of current transfer is needed. Electrical connection is made through some external means while connection is made via current collectors and conductive interconnects. The individual cells can be connected either in parallel or in series.
If the cells are connected in parallel then current-carrying busses can be provided to which all anodes or all of the cathodes are connected. If the cells are connected in series then interconnects must be provided between the anode of one cell and the cathode of another cell, usually the adjacent cell. By combining the methods of electrical interconnection described above it is possible to produce a wide variety of manifolded structures.
The invention is described below with particular reference to the drawings.
FIG. 1 is a schematic of a side feed fuel cell (10) design. The compliant current conductor or leads 12 and 14 positioned between cell interconnects 15 allow the thin electrode/electrolyte/electrode trilayer 20 to flex rather than break under mechanical and thermal loads. On the fuel side supplied by fuel tube 16 the current conductor 12 can be a nickel felt or thin metal foil bent into a helix. On the air side supplied by air tube 18 the conductor 14 can be an oxidation resistant metal or a conductive oxide in a variety of geometrical forms, felt or flexible thin helixes being two possibilities.
One preferred structure of the fuel cell is illustrated by FIGS. 2 (exploded view), and 3 (cross-section view), which show a unit cell of the stack. Both figures are schematic diagrams of a center feed fuel cell design (25) with a non-planar electrode/electrolyte/electrode foil (electrolyte sub-assembly) 30, as well as compliant/flexible current leads 32 and 34 shown in FIG. 3. FIG. 2 is a schematic exploded view of a centrally and/or internally manifolded solid oxide fuel cell (SOFC) stack "repeat unit" showing use of perforated metal manifold tubes 35 and 36 in a perforated ceramic tube 38 for gas delivery to the electrodes (anode 62 and cathode 64), with baffle rings 40 to prevent fuel/air mixing. FIG. 3 is a cross-sectional view of the repeat unit of FIG. 2 showing delivery of fuel and air, and use of fibrous mats 32 and 34 as current collectors. The fuel cell of this embodiment utilizes central manifolding tube sections through which the oxidizer and fuel respectively, pass, i.e., center feed, circular sub-assemblies with a central conduit. The electrolyte sub-assemblies 30 are stacked with manifolding tube sections. The outer-most ceramic tube section 38 has porous or perforated rings 55 which act as gas diffusers. Inside this ceramic tube are the two gas delivery manifolding tubes 35 and 36, one for the oxidizer (air) and one for fuel, which contain perforations 58 and 59 respectively, at the appropriate intervals.
The oxidizer and fuel exit the delivery manifold tubes, pass through the ceramic tube perforations 55, through the separator felt, wool, or fibrous mats 32 and 34 and come into contact with the anode 62 or cathode 64. Fuel and oxidizer are prevented from mixing within the annulus (between manifolding tubes and ceramic tubes) by metal or ceramic baffle disks 67 which are spaced at the same intervals as the electrolyte sub-assemblies and the metal interconnects 74. The gas delivery tubes 35 and 36, interior to the ceramic tube 38, are preferably made of an oxidation resistant metal such as those used for the separator disks. Finally, the thin and flexible electrolyte sub-assembly (30) consists of an anode/electrolyte/cathode sandwich, 62/63/64, preferably formed from sintered sheets of yttria partially stabilized or fully stabilized zirconia (TZP or YSZ), in which a central hole for gas passage is provided.
The thin sintered electrolyte layer can be formed as disclosed in U.S. Pat. No. 5,089,455. The electrodes may be slurry-coated or screen printed on both sides of the fully dense electrolyte disks. Both electrodes are then fired in air producing porous but adherent electronic conducting layers. The cathode can be a conducting perovskite ceramic such as lanthanum manganite, while the anode layer can be made from a mixture of yttria stabilized zirconia and nickelous oxide powders. The anode is reduced during operation in the fuel to a porous, conducting Ni-zirconia cermet.
The operation of the unit is done by providing fuel and air to the manifold, and the unit is brought to a sufficiently high temperature so that the electrolyte is conductive enough to sustain the reactions at the electrodes at rates required to draw the desired power. The current is drawn from the fuel cell by attaching leads to the first and last metal disks.
Another embodiment of the fuel cell uses concentric air and fuel manifold tubes 82 and 84 respectively within the ceramic tube 38. It is shown in FIGS. 4 (exploded view), and 5 (cross section). As the figures show, the porous or perforated ceramic rings 55 and the gas seal baffles 67 in the annular space are similar to those shown in FIGS. 2 and 3. However, in the concentric design, between the cathode 72 and adjacent metal interconnect 74 the inner-most air tube 82 must feed through the fuel tube 84 via air side tubes 82a. Therefore, gas tight weld seals 85 are needed at this intersection to prevent mixing of air and fuel in the fuel manifold tube.
In yet another embodiment of the invention the central manifolding tube is replaced by two or more manifolding tubes. This example is shown in the schematic diagrams of FIGS. 6 (exploded view), and 7 (cross section). As shown in the drawings, porous and non-porous spacers 95 and 96 respectively, are attached to the sub-assembly, and connected to the metal interconnect disks 102 and 104 from both the anode (90) and cathode (97) sides of electrolyte 93. Porous spacers 95 are used in the central air passage 92 on the cathode sides of each sub-assembly, while the fuel passages 94 have non-porous spacers 96 so that only air can diffuse along this level. On the anode side of the sub-assembly the fuel passages have porous spacers, while the air passage has a non-porous spacer. The separation distance between the electrolyte sub-assembly 100 and metal interconnect disks 102 and 104 respectively is determined by the spacer height. The cross-sectional view of FIG. 7 shows the basic repeat unit of a fuel cell generator (metal disk/spacers/sub-assembly/spacers), which is then repeated to form the manifolds. Each metal disk/sub-assembly/metal disk makes up a manifold layer.
Each embodiment described above may have other configurations. For instance, the sub-assemblies may be ordered so that the anodes of the adjacent sub-assemblies face each other. Again the current is collected using a porous current collector, but in this configuration additional bus-bars are provided.
A conductive wool or felt between the sub-assembly and each metal interconnect disk allows a low stress way of separating the sub-assembly and metal disk layers. At the same time the felts permit the diffusion of the gases to each electrode, while also electrically connecting them to the metal disks for current collection or electrical connection of sub-assembly cells. The anode felt 106 could be made of Ni, while the cathode side felt 108 could be an Ag-Pt coated fibrous mat.
In a comparative example, we prepared a finite element thermo-stress model of a 30 micron thick planar, flat plate electrolyte membrane measuring 3 inches in diameter with a 1/2 inch diameter center hole, with an outer edge at 800° C., and inner edge at 25° C. (10 micron thick air electrode, 10 micron thick electrolyte, 10 micron thick fuel electrode) with the elastic modulus of room temperature dense zirconia -3 mole % yttria (200 GPa) and the thermal expansion coefficient of dense zirconia (110×10-7/° C. from 25-1000° C.). We imposed a steady state thermal gradient of 800° C. from the edge to the center of a 3 inch (7.62 cm) diameter disk with a 0.5 inch (1.27 cm) hole in the center to mimic both the temperature gradient and stresses that could occur during rapid heating (start-up) of a center feed fuel cell design such as shown in FIG. 2. We found that the stresses in this model were perfectly symmetric and no bending occurred. Without bending this thermal gradient will produce stresses of over 240 Kpsi (1.65 GPa) at the inner surface of the half inch hole in this model. This stress will shatter almost all ceramic materials and this type of stress precludes the use of a flat ceramic electrolyte that can not bend in rapid heating situations. This stress is indicative of what a thick plate solid oxide fuel cell will experience.
To illustrate the advantages of the present fuel cell design, in another example, we prepared a finite element thermo-stress model of the same thirty micron thick membrane non-planar structure (a very shallow cone shape) with a cone height of 0.1 inch (0.254 cm), 30 microns thick, 3 inches in diameter with a 1/2 inch diameter center hole, outer edge at 800° C., inner edge at 25° C. We found the maximum stresses were a factor of 40 lower than observed in the planar model, i.e. less than 6 Kpsi (41 MPa). Most ceramic electrolyte materials can withstand such a stress. This stress model illustrates the marked reduction in stress which can be achieved by using thin, flexible electrolytes.
Table I lists the maximum stresses present as a function of cone height. With a cone height of 0.5 inches (1.27 cm) the maximum tensile stresses drop below 1,000 psi (6.89 MPa). It is possible to make such cone shaped electrode/electrolyte/electrode trilayers either by sintering into a cone shape or by plastic deformation at high temperature.
TABLE I______________________________________Cone height Maximum stress Minimum stressInches (cm) Kpsi (MPa) Kpsi (MPa)______________________________________0.0 {flat} 247 (1,700) -81.3 (-558)0.001 (0.0025) 353 (2,432) -81.4 (-561)0.005 (0.0127) 125 (861) -86.1 (-593)0.01 (0.0254) 61.9 (426) -50.7 (-349)0.05 (0.127) 11.3 (78) -11.9 (-82)0.1 (0.254) 5.5 (38) -6.1 (-42)0.5 (1.27) 0.98 (6.8) -1.2 (-8.3)______________________________________
Table II lists the maximum stresses in a finite element model of a corrugated disk 8 inches (20.32 cm) in diameter with a 0.2 inch (0.508 cm) diameter hole in the center with an 800° C. to 25° C. steady state temperature gradient imposed from edge to center. Again the disk was thirty microns thick with the elastic modulus of dense zirconia -3 mole % yttria at room temperature. The corrugation height is 0.1 inch (2.54 mm) or 0.2 inch (0.508 cm) and the corrugations were concentric around the center hole and evenly spaced from the center to the edge.
TABLE II______________________________________Maximum stresses in Kpsi (MPa)Number of Corrugation Heightcorrugations 0.2 inch (0.508 cm) 0.1 inch (0.254 cm)______________________________________3 2.755 (18.98) --5 2.002 (13.79) --7 1.756 (12.10) --9 1.840 (12.68) 4.208 (29.00)11 2.219 (15.29) 3.445 (23.74)13 -- 3.413 (23.52)15 2.350 (16.19) 3.201 (22.06)17 -- 3.311 (22.81)______________________________________
These finite element models prove that a thin flexible non-planar electrolyte that is free to bend and flex through compliant current connections can have extremely low stresses under thermal shock conditions and will survive rapid heating that fuel cell designs with thick flat plate electrolytes cannot.
EXAMPLES
The round disks referred to in the following examples, the electrolyte and particularly the electrolyte/electrode foils, are not flat in that the disk in all the examples had bumps or waves of greater than 200 microns in height, i.e., more than a 600:1 diameter to height ratio.
1) The edge of an approximately fifteen micron thick disk of zirconia -3 mole % yttria was put into the flame of a propane gas torch. The edge of the sample heated to over 1000° C., probably more than 1400° C., in less than about three seconds. The sample did not break or crack. This was repeated more than fifteen times. This simple experiment proves that a thin ceramic electrolyte with enough strength can be very thermal shock resistant if allowed to flex. Over a hundred samples of thickness ranging from about 5 microns to about 35 microns of zirconia -3 mole % yttria, zirconia -4 mole % yttria and zirconia -3 mole % yttria +20 wt. % alumina have survived similar treatment.
2) The edge of an approximately fifteen micron thick disk of zirconia -3 mole % yttria with porous platinum electrodes approximately ten microns thick on both sides was put into a propane torch as in example one. This fuel cell electrode/electrolyte/electrode tri layer did not break or crack even after over twenty of these extreme thermal cycles. This proves a fuel cell trilayer can be extremely thermal shock resistant if the trilayer is allowed to elastically bend and deform.
3) A round disk of zirconia -3 mole % yttria disk about 13-15 microns thick and 1 and 9/16 inch diameter was placed on an electrical heater and cycled from approximately 150-200° C. to about 700° C. over 4,000 times. For this experiment, we used as the heater, a metal honeycomb electrically heated catalyst (EHC, from Coming) having a serpentine electrical path. It took about 1 minute to heat up, held at about 700° C. for one minute and then cooled over two minutes for a total cycle time of about 4 minutes. The sample did not fracture or crack. Optical microscopy showed no sign of water vapor/stress degradation.
4) A rectangular piece of zirconia -3 mole % yttria about 30 microns thick, 7/16 inch long by 3/8 of an inch wide was mirror polished to a 0.3 micron diamond paste finish. This sample underwent the same thermal cycle as Example 3 but only for slightly more than 3,700 cycles in ambient humidity for late November in Coming N.Y. This sample was examined by optical microscopy, including a Nomarsky interference microscope (Nikon Microphot-FX), and examined for surface roughness. No surface roughness was found, indicating that there is no water vapor corrosion in these materials under these conditions.
5) Five strips of aluminum foil about 3 mm wide, about 25 microns thick, were wound into a helical shape about 3 to 4 mm in diameter and about 3 cm long. The helix was stretched so that a gap of 0.5 to 1 mm was present between the adjacent turns on the metal coil. These five helixes were bonded between two 3 cm×3 cm zirconia membranes about 25 microns thick. Both sheets could be flexed and the helixes would bend slightly also. Room temperature flexing showed that this electrolyte foil could be bent to more than several millimeters out of shape with no fracture even with the aluminum foil helixes attached.
6) Three strips of Kanthal A-1 (available from Kanthal AB, Hallstahammar, Sweden) heat resistant alloy about 2 mm wide and 50 microns thick were wound into a helical shape about 3-4 mm in diameter and about 3 cm long. The helix was stretched so that a gap of 0.5 to 1 mm was present between adjacent turns on the coil. The three coils were bonded between two 3 cm by 3 cm zirconia membranes about 25 microns thick with double stick tape. The two zirconia foils could be flexed and the Kanthal metal coils would flex also. The sample was not thermally tested. However, room temperature flexing showed that the electrolyte foil could be bent to more than several millimeters out of shape without fracture even with the Kanthal foil helixes attached.
7) In this example, the electrolyte and electrode combination formed a slight dome shape with the height of the dome about 3 mm high on each electrolyte/electrode combination sheet. (La,Sr)MnO3 electrodes were tape cast on one side each of two zirconia -3 mole % yttria electrolyte foils, about 25 microns thick and in an octagon shape about 7 cm from flat octagon side to flat octagon side. Seven Kanthal A-1 helixes were made as above. The helixes were dipped into (La,Sr)MnO3 slip and placed between the two coated electrolytes. A small weight was placed on the top of the electrolyte/electrode combination and the structure was fired at 1200° C. in air for two hours. The electrode structure after firing was porous, less than 25 microns thick and electrically conductive. The thermal expansion match was not perfect as the edges of the electrolyte/electrode foil curled slightly. The current connection coil structure did bond to the electrode layer. This two layer fuel cell structure flexed slightly without bond failure. The structure was electrically conductive from one octagon electrode layer to the second octagon electrode layer. The structure was thermal cycled from about 250° C. to about 700° C. more than 700 times with a three minute heating and a three minute forced air (fan) cooling cycle (for a total cycle time of 6 minutes). The electrolyte/electrode foil showed no damage. However, some of the sintered bonds between the current lead coils and the foil did break. After 1,400 thermal cycles the majority of the helixes bonds had broken but the electrode/electrolyte foils showed no damage. Post-test examination showed that very little of the (LaSr)MnO 3 slip remained on the top surface of the helixes while the bottom of the coils had too much material and was thick, but bonded. The material flowed when the coils were placed on the octagons.
The above examples show that if flexible current connections are accomplished, thin flexible electrode/electrolyte bi- and tri-layers can survive extreme thermal shock conditions. Such thermal shock conditions are expected when solid oxide fuel cells are used for electrical power in automobiles.
While the invention has been described above with respect to specific examples, these examples are not intended to be limiting as it will be clear to persons skilled in the art that numerous modifications and variations may be introduced without deviating from the scope and spirit of the invention.
|
Fuel cell designs incorporating non-planar inorganic electrolyte membranes offer improved mechanical and thermal shock resistance for mobile power generation systems, e.g., for high temperature fuel cell applications using liquid fuel (diesel and gasoline) and air for automobile power plants and other power systems requiring only intermittent high-temperature fuel cell operation.
| 7
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to a disposable cup holder for holding a cup and more particularly, to a scald-preventive disposable cup holder.
[0003] 2. Description of the Related Art
[0004] Disposable paper or plastic cups are intensively used in coffee shops, fast-food chain stores, drive-through restaurants, etc., for holding coffee, beverage, soup, or the like for takeout ordering. However, it is scalding to hold a hot cup directly with the hands. Some shops may provide clients with a paper cup holder for holding the cup, preventing direct contact of the hands with the cup. However, conventional paper cup holders simply have a barrel-like cup body without handle. A cup holder of this design simply postpones transferring of heat energy from the cup to the user's hand. The high temperature of the content carried in the up will still be transferred to the user's hand, causing the user to feel uncomfortable.
SUMMARY OF THE INVENTION
[0005] The present invention has been accomplished under the circumstances in view. It is the main object of the present invention to provide a cup holder, which has a scald-preventive handle that effectively reduces transferring of heat energy from loaded cup to the user's hand. It is another object of the present invention to provide a scald-preventive cup holder, which is made of inexpensive paper material for disposable use. It is still another object of the present invention to provide a scald-preventive disposable cup holder, which is easy and inexpensive to manufacture.
[0006] To achieve these and other objects of the present invention, the scald-preventive disposable cup holder comprises an endless peripheral wall formed of paper material, and a through hole defined by the endless peripheral wall and extending through top and bottom sides thereof, wherein at least one z, 900 -shaped cut is formed in the endless peripheral wall for enabling a part of the endless peripheral wall to be turned outwards from the endless peripheral wall to form at least one handle.
[0007] Further, protruding ribs may be formed on the inner or outer surface of the endless peripheral wall to provide a heat isolation effect.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is a perspective view showing the collapsed status of a scald-preventive disposable cup holder with two -shaped cuts at two sides according to the present invention.
[0009] [0009]FIG. 2 is similar to FIG. 1 but showing one handle turned out of the respective paper sheet material.
[0010] [0010]FIG. 3 illustrates the cup holder opened for the loading of a cup according to the present invention.
[0011] [0011]FIG. 3A is a schematic drawing showing a cup holder of double-layer paper material for the loading of a cup according to the present invention.
[0012] [0012]FIG. 4 is a perspective view showing the collapsed status of a scald-preventive disposable cup holder with one -shaped cut for one single handle according to the present invention.
[0013] [0013]FIG. 5 is similar to FIG. 4 but showing one handle turned out of the respective paper sheet material.
[0014] [0014]FIG. 6 shows the open status of the cup holder shown in FIG. 4.
[0015] [0015]FIG. 7 is a top plain view of a cup holder with ribs on the outside wall according to the present invention.
[0016] [0016]FIG. 8 is a front plain view of the cup holder shown in FIG. 7.
[0017] [0017]FIG. 9 is a plain view showing a cup held in the cup holder according to the present invention.
[0018] [0018]FIG. 10 is a top plain view of a cup holder with ribs on the inside wall according to the present invention.
[0019] [0019]FIG. 11 is a front plain view of the cup holder shown in FIG. 10.
[0020] [0020]FIG. 12 shows a cup held in a barrel-like cup holder according to the present invention.
[0021] [0021]FIG. 13 illustrates the collapsed status of a cup holder formed of two narrow elongated strips of hard paper with extension lugs at both ends of each elongated strip of hard paper according to the present invention.
[0022] [0022]FIG. 14 shows the open status of the cup holder shown in FIG. 13.
[0023] [0023]FIG. 15 illustrates the collapsed status of a cup holder formed of two narrow elongated strips of hard paper with one extension lug at one end of each elongated strip of hard paper according to the present invention.
[0024] [0024]FIG. 16 shows the open status of the cup holder shown in FIG. 15.
[0025] [0025]FIG. 17 shows the open status of a rectangular cup holder according to the present invention.
[0026] [0026]FIG. 18 shows another alternate form of rectangular cup holder according to the present invention.
[0027] [0027]FIG. 19 is a perspective view of still another alternate form of the cup holder according to the present invention.
[0028] [0028]FIG. 19A is a perspective view of still another alternate form of the present invention, showing the folded status of the extension lugs.
[0029] [0029]FIG. 20 is a perspective view of still another alternate form of the present invention, showing a single hole formed in the bonded extension lugs for handle.
[0030] [0030]FIG. 21 is a perspective view of still another alternate form of the present invention, showing two holes formed in the bonded extension lugs for handle.
[0031] [0031]FIG. 22 is a schematic drawing showing an I-cut on the bonded extension lugs according to the present invention.
[0032] [0032]FIG. 23 is a schematic drawing showing a double Y-end cut on the bonded extension lugs according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0033] Referring to FIG. 1, two certain thickness paper sheet materials are arranged in a stack and stamped into a cup holder 1 subject to the desired shape. During shape forming, two substantially -shaped cuts 11 are formed in the cup holder 1 at two opposite sides, thereby forming two handles 13 . Further, two vertical folding lines are formed in the cup holder 1 at two sides and extended to the top and bottom edges of the cup holder 1 for folding. Each handle 13 has one side connected to the cup holder 1 by a connection line 12 , which allows the respective handle 13 to be turned in and out of the respective -shaped cut 11 , and a finger hole 14 . The finger hole 14 can be made having any of a variety of shapes. When extended out, the finished cup holder 1 is shaped like a tapered stub tube for holding a cup. Further, the bottom edge 10 of the cup holder 1 is smoothly upwardly curved (this will be explained further).
[0034] The two handles 13 are respectively turned out of the respective -shaped cuts 11 of the cup holder 1 (see FIG. 2), and then the cup holder 1 is extended out (stretched into the three-dimensional operative shape). Alternatively, the cup holder 1 can be extended out before turning the handles 13 out of the respective -shaped cuts 11 of the cup holder 1 . Thus, a cup 2 can be inserted into the cup holder 1 and rested therein as shown in FIGS. 3 and 9. When using the cup holder 1 to hold a cup 2 containing hot water, the user can hold the handles 13 with the fingers, preventing direct touch of the fingers with the peripheral wall of the cup holder 1 that absorbs heat from the hot water contained in the cup 2 . As indicated above, the cup holder 1 is shaped like a tapered stub tube having a relatively bigger inner diameter in the top side and a relatively smaller inner diameter in the bottom side, it holds the cup 2 firmly in place. Further, because the bottom edge 10 of the cup holder 1 is smoothly upwardly curved, it has a certain prestress for supporting the load of the cup and the contained substance in the cup.
[0035] The cup holder 1 can be made of a double-layer paper material, having the outer layer of the double-layer paper material properly cut to form the desired handles 13 and the inner layer of the double-layer paper material printed with a logo at the location corresponding to the handles 13 (see FIG. 3A).
[0036] According to the second embodiment of the present invention as shown in FIGS. 4 ˜ 6 , two certain thickness paper sheet materials are arranged in a stack and stamped into a cup holder 1 shaped like a tapered stub tube for holding a cup. During shape forming, one substantially -shaped cut 11 is formed in the cup holder 1 , thereby forming a handle 13 . The handle 13 has one side connected to the cup holder 1 by a connection line 12 , which allows the handle 13 to be turned in and out of the -shaped cut 11 , and a finger hole 14 . The finger hole 14 can be made having any of a variety of shapes.
[0037] According to the third embodiment of the present invention as shown in FIGS. 7 and 8, the cup holder 1 has vertical ribs 11 protruded from and equiangularly spaced around the outside wall. The vertical ribs 11 increase the wall thickness of the cup holder 1 . When holding the cup holder 1 with the fingers, the fingers are in contact with the vertical ribs 11 , less heat energy will be transferred from the cup held in the cup holder 1 to the user's fingers.
[0038] According to the fourth embodiment of the present invention as shown in FIGS, 10 and 11 , the cup holder has vertical ribs 11 protruded from and equiangularly spaced around the inside wall. The vertical ribs 11 increase the wall thickness of the cup holder 1 . When holding a cup with the cup holder 1 , the vertical ribs 11 support the cup in place, and therefore less heat energy is transferred from the cup held in the cup holder 1 to the peripheral wall of the cup holder 1 .
[0039] Further, corrugated paper material may be used to make cup holders, achieving the desired heat insulation effect. A cup holder can also be made having raised portions protruded from the inside or outside wall.
[0040] According to the fifth embodiment of the present invention as shown in FIG. 12, the cup holder 1 is made having the same inner diameter in the top side as well as the bottom side for holding a cylindrical can food or beverage.
[0041] According to the sixth embodiment of the present invention as shown in FIGS. 13 and 14, the cup holder 3 is formed of two narrow elongated strips of hard paper. The two narrow elongated strips of hard paper of the cup holder 3 each have two extension lugs 31 at the ends. The extension lugs 31 of the two narrow elongated strips of hard paper are bonded together, forming a respective handle. After bonding of the extension lugs 31 , the two narrow elongated strips of hard paper of the cup holder 3 are stretched into an open status, thereby forming a circular cup holder.
[0042] According to the seventh embodiment of the present invention as shown in FIGS. 15 and 16, the cup holder 3 is formed of two narrow elongated strips of hard paper. The two distal ends of the narrow elongated strips of hard paper are respectively bonded together. Each narrow elongated strip of hard paper has an extension lug 31 at one end for forming a handle. After bonding of the ends of the two narrow elongated strips of hard paper, the two narrow elongated strips of hard paper are stretched into an open status, thereby forming a circular cup holder.
[0043] Alternatively, the cup holder 3 can be made having a rectangular shape with extension lugs 31 at two sides as shown in FIG. 17. FIG. 18 shows another alternate form of rectangular cup holder according to the present invention.
[0044] According to still another alternate form of the present invention as shown in FIG. 19, the cup holder 3 is formed of a narrow strip of hard paper curved into a barrel-like shape, having two extension lugs 31 respectively extended from the two distal ends and bonded together, thereby forming a handle.
[0045] According to still another alternate forms of the present invention as shown in FIGS. 20 and 21, hole or holes 311 are formed in the bonded extension lugs 31 of the cup holder 3 . Making a cut 312 , for example, a crossed cut (see FIGS. 20 and 21), I-cut (see FIG. 22), or double Y-end cut (see FIG. 23) on the bonded extension lugs 31 and then inserting the finger through the cut 312 form a hole 311 in the bonded extension lugs 31 of the cup holder 3 .
[0046] [0046]FIG. 19A shows still another alternate form of the present invention. According to this embodiment, the cup holder 3 is formed of a narrow strip of hard paper curved into a barrel-like shape, having two extension lugs 31 respectively extended from the two distal ends and bonded together, thereby forming a handle. Each extension lug 31 has a first lug portion 31 A, a second lug portion 31 B, a third lug portion 31 C, and a respective vertical folding line 31 D between the first lug portion 31 A and the second lug portion 31 B and between the second lug portion 31 B and the third lug portion 31 C. Each extension lug 31 is folded inwards along the respective vertical folding lines 31 D to have the first lug portion 31 A and the second lug portion 31 B bonded together and the third lug portion 31 C bonded to the inside wall of the cup holder 3 . Further, the cup holder 3 has a vertical folding line 31 E on the middle remove from the handle (the extension lugs 31 ). Through the vertical folding line 31 E, the cup holder is collapsed into a flat manner.
[0047] A prototype of scald-preventive disposable cup holder has been constructed with the features of FIGS. 1 ˜ 23 . The scald-preventive disposable cup holder functions smoothly to provide all of the features discussed earlier.
[0048] Although particular embodiments of the invention have been described in detail for purposes of illustration, various modifications and enhancements may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited except as by the appended claims.
|
A scald-preventive disposable cup holder is disclosed to have an endless peripheral wall formed of paper material, a through hole defined by the endless peripheral wall and extending through top and bottom sides thereof, a
| 1
|
This application is a continuation of application Ser. No. 07/355,021, filed May 22, 1989 now abandoned.
FIELD OF THE INVENTION
This invention relates to metal sheeting.
DESCRIPTION OF THE PRIOR ART
Metal profiled sheets are frequently used as roof panels and for other building cladding purposes. It is well known to provide a metal sheet which is pre-formed with integral ribbing so that it may readily be interlocked at adjoining edges with a similar sheet and which may be fastened to a support without the fastening means being exposed to the environment or being on the visible side of the sheet. These products may include separate fixing clips and involve on site roll forming to close the interlocking seams. All such products are usually referred to as "raised seam cladding". Many examples of such profiled sheets are known and they are frequently roll-formed from an aluminium alloy as well as other metallic materials. Usually each sheet has a first upstanding hook formation along one edge and a second upstanding formation along an opposite edge of the sheet with a hook receiving part and a valley in the plane of the sheet through which fasteners can be passed. When the sheets are interlocked the first formation of one sheet hooks on to the hook receiving part of an adjoining sheet and covers the valley and its fasteners. From their outer surfaces the sheets then present a generally flat appearance having spaced apart upstanding ribs with no fasteners visible. These ribs are usually referred to as "raised seams".
In general, when used as roof panels, the sheets need to be fully supported on a pre-prepared flat surface and are not strong enough to span any worthwhile distance between supporting purlins. It is however clearly desirable to provide sheets that can be supported at intervals, as between spaced apart purlins, and it is further desirable that the sheet should be wider so that the spacing between the raised seams is increased. In addition the sheets should be strong enough to support snow loads, wind loads both in pressure and suction and so that, for example, operatives can walk on them.
SUMMARY OF THE INVENTION
We have found that there are conflicting factors between, on the one hand, increasing the strength and stiffness of the sheet and, on the other hand, ensuring adequate locking against suction forces under high wind conditions.
It is therefore an object of the present invention to provide an improved interlocking metal sheet which has good strength characteristics and improved interlocking formations.
According to the present invention there is provided a metal sheet having a first upstanding hook formation along one edge and a second, upstanding hook receiving formation and a valley along an opposite edge, the arrangement being such that the sheet can be fastened directly to a support without the interposition of separate clips and so that the first formation of one sheet can hook over the second formation of an adjoining sheet and cover its valley, this arrangement being characterised by latching means acting between the formations so that, after interlocking the sheets, said one sheet can be rotated about the hook receiving formation of the other sheet through at least 25° before the formations can be disengaged.
The rotation preferably occurs without significant distortion of the material of either sheet.
Preferably upon said relative rotation the latching action ceases to function, and further rotation, through at least 10° is required before the formations can be disengaged.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a transverse section through a metal sheet.
FIG. 2 is a view similar to FIG. 1 showing part of two sheets distorted by suction forces.
FIG. 3 is a similar section, to a larger scale, of an interconnection between two metal sheets.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1 a roll-formed aluminium alloy sheet 1 has along one side edge 2 a first hook formation indicated generally at 3 which is upstanding from the outer surface 4 of the sheet. At its other side edge 5 the sheet has a second, or hook receiving, formation indicated generally at 6 and a valley 7. The formations 3 and 6 are separated by a web 8 which is coplanar with the floor 9 of the valley 7. A number of stiffening ribs 8b may be formed in the sheet.
The hook formation 3 comprises an upwardly and outwardly sloping part 10, a wall 11 approximately at right angles to the web 8, a flat 12, a downwardly and outwardly projecting part 13 and an upwardly and inwardly projecting part 14, the parts 13 and 14 constituting a hook having a curved part 15. As shown the outer end of the part 14 is curved to be approximately parallel with the wall 11 and to allow run-out on the edge of the sheet material on roll forming.
The hook receiving formation 6 comprises an upwardly and outwardly sloping part 16 the upper end 16b of which is approximately at right angles to the web 8 and is then folded at a part 17 which, together with the wall 16b defines a hook receiving formation as will be described later. The lower end of the folded part 17 is formed as a hollow bead 18 and the rolled material of the sheet is then formed as a platform 19 with a recess 20, a side wall 21 approximately at right angles to the web 8 leading to the valley 7, the floor 9 of which has an upwardly turned part 22 and a lip 23 at the same angle to the web 8 as the sloping part 10. The lip 23 allows run out of the edge of the sheet material on roll forming.
FIG. 3 shows how the hook formation 3 engages over the hook receiving part 6 of an adjoining sheet. In FIG. 3 the same reference numerals have been used except that for the "adjoining" sheet suffixes "a" have been added to each reference numeral.
It will be assumed that the sheet 1a is already mounted on suitably spaced-apart purlins (not shown) and secured thereto through the valley floor 9a. The fixings used can be conventional and may be arranged to accommodate longitudinal expansion of the sheet 1a. The sheet 1 is then held with its web 8 approximately vertical and its hook formation 3 engaged around the bead 18a. The sheet 1 is then pivoted through sections D-A- to the final latched position shown in cross-hatched lines in FIG. 3. In the final latched position, in which the sheet is secured to the purlins, the sloping part 10 engages with the lip 23a and the wall 11, the flat 12, the part 13 and the curved part 15 respectively embrace the upper part of the side wall 21a, the platform 19a, the part 17a and the curved part 15a. Sealing material (not shown) may be disposed in the recess 20a. The dimensions of the formations 3 and 6 are such that the upper part of the formation 3 is a "latching fit" over the upper part of the formation 6.
As mentioned above we have found that conflicting requirements exist in increasing the strength of the sheets without at the same time increasing the risk that suction forces under high wind conditions will tear off one of the sheets. When the sheets are mounted on spaced-apart purlins this reduces the number of edge fastenings that can be used.
Although innately higher strength aluminium alloys than are usually employed can be used, this does not of itself increase the strength of the sheets sufficiently. Increasing the height of the "raised seams" constituted by the formations 3 and 6 does significantly increase the strength of the sheets and enables them to be unsupported across suitably spaced purlins. However such a change significantly alters the pattern of distortion of the "other" sheet 1a raised by suction forces on the web 8a resulting from wind flow across the outer surfaces 4 and 4a of the sheets. This change tends to make easier the lateral separation of the formations.
As shown in FIG. 2, wind flow across the outer surfaces 4 and 4a can cause high suction forces to be applied to the webs of the sheets and lift these webs so that their formations 3 and 6 distort and move laterally to disengage the formations 3 and 6.
With the present invention the close "latching fit" engagement between the upper parts of the formations ensures that the wall 11 constitutes latching means for the hook by its close fit against the upper part of the side wall 21a. As shown in FIG. 3 the edge of the sheet 1 can rotate about the bead 18a through successive positions indicated at A, B, C and D before reaching the position E shown as a solid line. During the movement A to approximately C the wall 11 rides up the side wall 21a and retains its latching action. At the approximate position C the corner between the sloping part 10 and the wall 11 rides over the corner between the side wall 21a and the platform 19a. As a result of the "latching fit" referred to above this transition occurs suddenly. In positions D and E the hook still remains engaged since the outer end of the part 14 remains in engagement with a part of the bead 18a which extends parallel with the upper end of the sloping part 16. Once a sheet has been distorted to the extent represented in position E the strains to which it is subjected are extremely complex and not readily predictable. However it would be expected that position E represents the point at which the edge of the sheet 1 will move laterally and the formations will disengage.
In position C the chain line 25 represents the angle between the edge of the web 8 and the line of the web 8a. The angle defined is G.
In position E the chain line 24 represents the angle between the edge of the web 8 and the line of the web 8a. The angle defined is F. The precise angle F reached for position E is determined by the detailed dimensions of the upper parts of the formations 3 and 6, the width of the web 8 and the thickness of the sheet. We have found the following criteria achieve good results:
Height of the formations 3 and 6 is a minimum of 10% (preferably 12.5%) of the total sheet width. This is to achieve a basic stiffness to the whole profile so as to allow it to support the imposed loads.
Length of the vertical wall 11 is between 20% to 30% (preferably 24%) of the height of the rib formation 3 and 6.
Center of radius of tip of the hook receiving formation is in the range 10 to 20% (preferably 14%) below the top of the rib formation 6.
Distance of center of radius of tip of hook receiving formation to vertical wall 11 when assembled is in the range 3.75% to 6.25% (preferably 5%) of the total formation width.
Sheet thickness lies in the range 0.15% to 0.25% of the total formation width.
The angle G is in the range 25° to 30° (preferably 28°).
The angle F is in the range 10° to 35° greater than angle G (preferably 30°).
By using a high strength aluminium alloy such as 3105 or 3004 in standard roofing sheet thicknesses and tempers and by increasing the height of the raised seams, the basic strength of sheets 500 mm wide can be increased sufficiently to enable the sheets to span purlins with spacings in excess of 2.0 m and still readily support snow and wind loads both in pressure and suction and carry the weight of an operative between the purlins. By utilising the latching feature of the present invention the disadvantages of increasing the height of the seams can be obviated and increased protection given against suction induced by wind force.
It will be understood that with the interlocking formations described above then should the sheet 1 be rotated through an angle significantly greater than the angle F (position E) the sheets will again interlock as the part 14 extends upwardly behind the folded part 17. Depending upon the dimensions of these parts this reengagement is likely to occur with an angle F of about 75°.
|
A metal sheet (1) having a first upstanding hook formation (3) along one edge (2) and a second, upstanding hook receiving formation (6) and a valley (7) along an opposite edge (5) the arrangement being such that the sheet can be fastened directly to a support without the interposition of separate clips and so that the first formation of one sheet can hook over the second formation of an adjoining sheet and cover its valley characterized by latching means (11, 12, 13, 14, 15 and 16b, 17, 19, 21) acting between the formations so that after interlocking the sheets said one sheet can be rotated about the hook receiving formation of the other sheet through at least 25° before the formations can be disengaged.
| 4
|
FIELD OF THE INVENTION
The present invention relates to a method and a device for obtaining hot drinks in solution.
BACKGROUND OF THE INVENTION
It is known that the so-called traditional cappuccino is a mixture of two liquids, one based on coffee and the other based on milk, possibly emulsified by means of a steam nozzle, to the infusion of espresso coffee.
Units for emulsifying milk with air and steam are also known, and have a chamber into which an inflow pipe for the steam, an intake pipe for the milk, and an intake pipe for the air, flow. All these known devices nevertheless always involve adding the emulsified milk to the infusion of coffee which has been obtained separately. It is further known that automatic dispensers of hot drinks provide cappuccinos which are obtained by mixing a solution of milk with a solution of coffee, the mixture being obtained by agitation with electromechanical means.
SUMMARY AND OBJECTS OF THE INVENTION
The aim of the present invention is to propose a method and a device which make it possible to obtain, in a cup, hot drinks in solution such as cappuccino, coffee, chocolate, milk, tea, broth and similar drinks, using freeze-dried products.
For the cappuccino, the solution liquid is milk which can also be in natural form.
This aim has been achieved according to the invention by using an operational method which consists of:
forming a predetermined does of freeze-dried product;
loading the dose thus formed of freeze-dried product into a treatment chamber;
supplying the treatment chamber with a solution of liquid and possibly air with which to dissolve, mix and possibly emulsifying the freeze-dried product contained therein, obtaining the corresponding drink, the solution liquid and the air being supplied by means of steam under pressure;
collecting in a cup the drink thus obtained;
interrupting the supply of the steam and thus interrupting the supply of the solution liquid and of the air;
emptying the treatment chamber of the freeze-dried product into a collection cup for the drink.
In order to implement the method, a device is used, which is characterized in that it comprises:
means for forming a predetermined dose of freeze-dried product;
means for dissolving and mixing with the solution liquid, and possibly emulsifying with air, the predetermined dose of freeze-dried product, with a treatment chamber with which at least one inlet channel is associated for the admission of the solution liquid and of the air by means of steam under pressure;
means for supplying the solution liquid for the freeze-dried product and the emulsion air into the treatment chamber;
means for emptying the treatment chamber; means for the movement of the various moving parts, comprising a disk which rotates about a horizontal axis and is provided with a number of cams;
means for starting and stopping the device in the absence of steam under pressure.
The advantages obtained by virtue of the invention consist essentially in that the device is of economical construction, functions autonomously, that is to say, without the use of electric power, and operates according to a rapid, hygienic and reliable cycle even after a long period of use.
These and other advantages and characteristics of the invention will be understood to a greater and better extent by any expert by means of the description which follows and with the aid of the attached drawings, which are given by way of practical exemplification of the invention but are not to be considered in a limitative sense.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents a plan view of a device for obtaining cappuccinos with froth according to the invention in the start of cycle state;
FIG. 2 represents a front view of the device in FIG. 1 in the start and end of the cycle state;
FIG. 3 represents a partial lateral view of the device in FIG. 1 with a detail of the security lock;
FIG. 4 represents a front view of the kinematic motion of the device in FIG. 2 in the phase of loading of the coffee into the treatment chamber;
FIG. 5 represents a front view of the kinematic motion of the device in FIG. 2 in partial cutaway in the phase of production of the cappuccino with froth;
FIG. 6 represents in cross-section a detail of the intake unit for the mil for the device in FIG. 2;
FIG. 7 represents a detail of the treatment chamber for the device in FIG. 2;
FIG. 8 represents a cross-section according to D--D in FIG. 7;
FIG. 9 represents a detail of the intake pipe for the milk in the operational state;
FIG. 10 represents a cross-section according to B--B in FIG. 9, and
FIG. 11 represents a cross-section according to C--C in FIG. 10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reduced to its essential structure and with reference to the attached drawings, the method for obtaining cappuccinos with or without froth according to the invention consists of, in order, the following operational phases:
forming a predetermined dose of freeze-dried coffee;
loading the dose of coffee thus formed into a treatment chamber underneath;
closing the treatment chamber but allowing inlet of steam under pressure, of milk with emulsion air and allowing outlet of the cappuccino which is produced;
supplying, by means of steam under pressure, milk into the treatment chamber to dissolve and mix the coffee, and supplying air with which to emulsify the milk thus obtaining cappuccino with froth;
collecting the thus-formed cappuccino which flows from the treatment chamber into a cup;
interrupting the supply of steam under pressure and thus also interrupting the intake of the milk and the air;
emptying the treatment chamber into the cup for collection of the cappuccino.
Advantageously--according to the invention--it is envisaged that the predetermined dose of coffee is for one or more cups of cappuccino and that the capacity of the treatment chamber is independent of a cup of cappuccino.
Further, according to the invention, it is envisaged that all the arrangements for carrying out, in succession, the corresponding phases of the operational process are derived from a single control element.
As far as the device for implementing the method is concerned, it comprises, according to the invention:
A. Means for forming a predetermined dose of freeze-dried coffee, with a loader 1, as shown in FIG. 2, open in the region of the lower and upper ends. The loader 1 is integral with a body 10 which travels horizontally in a track 2 from a position for loading of the coffee, which is supplied by gravity from a magazine 3 above, to a position of discharge by gravity into a treatment chamber 4 underneath for the coffee. The travel is derived, by means of a connecting rod 5, with the movement of opening/closing, as shown in FIG. 4, of the cover 6 of the treatment chamber. The body 10 is closed at the top in order to intercept the mouth 30 of the magazine 3 during the outward travel, and during the return travel of the loader 1 from the treatment chamber 4. The body 10 is also associated with a lower plate 11 which is connected to the body 10 and slides in order to allow the lower plate 11 to intercept, at the bottom, the loader 1 during its entire travel, except in the position for discharging the coffee into the treatment chamber 4. At a higher level than the loader 1 and axially in relation to the treatment chamber 4, a diffuser 48 of downwardly flowing hot air is provided, with the function of cleaning the internal walls of the loader 1 after its emptying and with the further function of heating the walls so as to prevent the formation of condensation water there.
B. Means for dissolving and mixing the predetermined dose of freeze-dried coffee with emulsified milk in the treatment chamber 4 is provided. The treatment chamber 4 is provided with a cover 6 which rotates upwards, an outlet pipe 60 as shown in FIGS. 1 and 7, for removing the cappuccino just made, a lower opening 41, as shown in FIG. 4, for emptying with a sealing valve 7, and a lateral opening 40, FIGS. 5 and 6, for the admission of the milk and of the air by means of steam under pressure. It is envisaged that the opening 41 opens into a pipe 42, FIG. 8, which is prolonged in a tube 43, FIGS. 1, 2, 4, 5, 7, and 8, for the distribution of the cappuccino into a cup. Also the opening 41 opens into a flexible tube 61, FIGS. 1, 7 and 8, connected to the outlet pipe 60 of the cover 6 for the bringing forward of the cappuccino under formation. The cover 6 is rotated, in opening and in closing respectively, by a negative cam 20, FIG. 2, that is to say, one obtained by depression, in a disk 13. The disk 13 can rotate about a horizontal axis under the control of a hand-grip 13' which is integral with it. The valve 7 is controlled in closing and in opening respectively by a spring 70 and by a lever 71 which is subject to a positive cam 21 of the disk 13. The lever 71 being secured, in the closed state of the valve 7, by a further lever 72 which is subject to a corresponding positive cam 23 of the disk 13.
C. The means for supplying the milk solution and the air emulsion into the treatment chamber 4 comprises an intake chamber 8, FIGS. 5 and 6 which communicates with the treatment chamber 4. A steam pipe 80 for the steam under pressure, a pipe 9 for the milk, and an air channel 100 open into the treatment chamber 4. The steam under pressure, provided by a boiler (not shown in the drawing) is admitted into the intake chamber 8 through a nozzle 81 which is made to communicate with an operating cylinder 82 by means of an operating valve 83 which is opened by the piston of the same cylinder 82 when the latter is set in operation with the opening of the inlet valve 84 for the steam, under the action of a lever 85 which is subject to a cam 24 of the disk 13.
The milk is drawn into the intake chamber 8 through a calibrated nozzle 86, which is connected to an oscillating tube 87 which takes up from a receptacle 88, as soon as the inlet valve 89 is opened by means of the same lever 85 which operates the inlet valve 84 for the steam under pressure. The oscillation of the tube 87, from a horizontal rest position out of the milk to a vertical take-up position in the milk, is derived from a cam 25 of the movement disk 13.
Lastly, the ambient air is drawn into the intake chamber 8 through a channel 100, shown in FIGS. 10 and 11, delimited by a flattening made on the external surface of the hollow shank 87' of the tube 87. It goes without saying that the air channel 100 can be closed in order to obtain cappuccino without froth.
D. The means for starting and stopping the device in the absence of steam under pressure, comprises a bar 14, shown in FIG. 1, which is subject to a spring 16 and associated with the shaft of an operating cylinder 15. The operating cylinder 15 is set in operation by the same steam under pressure in such a manner that, with the cylinder 15 empt, the free end of the bar 14, under the action of the spring 16, engages the disk 13 in a corresponding slot 91, locking the rotation of the control hand-grip 13', and, with the cylinder 15 under pressure, the bar 14 recedes, releasing the disk 13 and the associated control hand-grip 13'.
The device which has been described and illustrated, by virtue of the presence of the hand-grip 13', is of the semi-automatic type, but any expert knows well that the setting in operation of the disk 13 for movement of the device can be automated with simple known means.
The functioning is as follows. At the start of each cycle, the cylinder 15 is under pressure, the disk 13 is released from the bar 14, but is retained by a tooth 92, as shown in FIG. 3, installed in a corresponding notch 93. The emptying valve 7 for the chamber 4 is open and the admission of steam, milk and air is intercepted. By rotating the hand-grip 13' in a clockwise direction by approximately 80°, the cover 6 of the chamber 4 is raised, the valve 7 closes, the dosing apparatus 1 advances and pours the dose of coffee in granules into the chamber 4; the hand-grip 13' is then rotated in a counterclockwise direction by approximately 160° in such a manner that the cover 6 is lowered and closes the chamber 4, the tube 87 is rotated by 90° towards the bottom, the lever 85 opens the valve 89 of the pipe 9 for the milk and the same lever 85 opens the inlet valve 84 for the steam in such a manner that the cylinder 82 is set in operation and the nozzle 81 towards the intake chamber 8 is opened. The steam arrives in the treatment chamber 4, drawing the milk by means of the tube 87 and the air through the channel 100 into the treatment chamber 4.
As the milk arrives in the treatment chamber 4, it is emulsified with the air and progressively dissolves the granules of coffee, producing cappuccino in an increasing quantity. When the treatment chamber 4 is full, the cappuccino flows through the outlet pipe 60 which is provided in the cover 6 and communicates with the tube 43 for distribution into the cup. When the desired quantity of cappuccino is collected, the hand-grip 13' is rotated in a clockwise direction by approximately 160°, to the initial position, so as to intercept the admission of the steam, of the milk, and of the air and to open the emptying valve 7 of the treatment chamber 4, thus restoring the start of cycle conditions.
In practice, however, the embodiment details can vary in equivalent manner in form, dimensions, arrangement of the elements, nature of the materials used, without moreover departing from the scope of the idea for solution adopted and therefore remaining within the limits of the protection accorded by the present patent of industrial invention.
|
A device for obtaining hot drinks in solution, especially hot drinks made from a freeze-dried product. The freeze-dried product is dispensed in a predetermined dose into a treatment chamber. The treatment chamber is closed and air, liquid, and steam are injected into the treatment chamber in order to dissolve the predetermined dose and to create the hot drink. The predetermined dose is substantially mixed and dissolved in the liquid, steam and air and removed from the treatment chamber through an outlet in a cover of the treatment chamber and through a valve in the bottom of the treatment chamber. The supply of air to the treatment chamber can be interrupted if the hot drink is desired without froth.
| 8
|
FIELD OF THE INVENTION
The invention related to prepolymeric polyols which contain mesogenic units in their molecular structure and more particularly to prepolymers which exhibit liquid crystalline properties.
SUMMARY OF THE INVENTION
Prepolymer polyols containing mesogenic moieties useful as reactants for the preparation of resinous materials are disclosed. Synthesized by condensing a polyether polyol with bifunctional mesogenic diacids or diesters. The compounds of the invention are characterized by their reasonably low melt temperature which renders them suitable as additive materials in polymeric molding compositions and as precursors for the preparation of resinous materials.
The liquid crystalline properties of the prepolymers of the invention were found to depend on the type and molecular weight of the glycols and on the molar ratio between the glycols and the mesogenic reactant.
BACKGROUND OF THE INVENTION
Liquid crystalline (mesogenic ) groups are moieties which can aggregate to form nematic, smectic or cholesteric ordering. The use of these compounds in the molecular structure of resinous materials has been proposed. It has for instance been proposed that the physical and barrier properties of polyurethanes may be improved by reacting a diisocyanate and/or polyisocyanate with a polyol containing mesogenic units.
The relevant art is noted to include "Liquid Crystal Polymers VII. Liquid crystalline polyesters of Trans-4,4'-stilbene dicarboxylic acid and aliphatic glycols" by W.J.Jackson, Jr. et al published in the Journal of Applied Polymer Science: Applied Polymer Symposium 41, 307-326 (1985), where a reaction of esters of trans-4,4'-stilbene dicarboxylic acid (SDA) with polymethylene glycols containing 4 to 10 methylene groups and several additional other glycols has been disclosed.
U.S. Pat. No. 4,412,059 disclosed a polymeric material comprising an optically active monomer. The material is said to be capable of forming a high modulus biaxially orientable structures of a cholesteric mesophase. Polymeric liquid crystals which retain their mesomorphic structure and properties at temperatures below the glass transition temperature are disclosed in U.S. Pat. No. 4,617,371. The polymers thus disclosed contain mesogenic and spacer units in alternating sequence. Relevant technology is also disclosed in U.S. Pat. No. 4,698,397 which relates to a cholesteric liquid crystal copolyester and in U.S. Pat. No. 4,745,135 which disclosed a polyol which contains liquid crystalline moieties. A significant difference between the present invention and the '135 document resides in the selection of the respective polyol systems. An organic bulk polymer containing microscopically dispersed therein liquid crystalline polymer has been disclosed in U.S.Pat. No. 4,798,849.
DETAILED DESCRIPTION OF THE INVENTION
In the synthesis of the prepolymer polyol of the present invention a mesogenic diacid or the corresponding diester conforming to ##STR1## where R is, --CH 2 CH 2 --, --CH═CH--, --C.tbd.C--, --OCH 2 --, --CO 2 --, --CH═N--, --N═N-- and where R' is --H, --CH 3 , --CH 2 CH 3 and where R"' denotes hydrogen, alkyl, alkyl aryl, aryl, alkyl ether, aryl ether, halogen, trialkyl silyl or trifluoromethane, and where m is 1 to 4, is condensed with at least one polyether polyol conforming to ##STR2## where R" is at least one of --H and --CH 3 and n is 0 to 45, preferably 0-22, most preferably 2-10. Importantly, the prepolymer polyol of the invention is imparted liquid crystalline properties by selecting a polyether polyol where R" is hydrogen, n is about 1 to 4 and the mole ratio between the glycol and mesogenic reactants is about 2:1 to 9:8, preferably 3:2 to 9:8. most preferably 4:3 to 7:6.
The condensation reaction, in the presence of a suitable catalyst, is carried out at a temperature of about 240° C.
Suitable catalysts include titanium tetraisopropoxide, dibutyltin dilaurate and the acetates of manganese, cobalt, zinc, titanium, antimony, barium, calcium, magnesium and cadmium.
The preferred catalyst is titanium tetraisopropoxide.
The product of the reaction is characterized in that its molecular weight, as determined from the OH number, is about 356 to 4000, preferably 1000 to 2500 and in that it conforms structurally to ##STR3## where x is an integer of 1 to 8, preferably 2 to 5 and where R, R", R"', m and n are as noted above.
Importantly, the mole ratio between the polyether polyol and the mesogenic diester is in the range of from 2:1 to 9:8 preferably 3:1 to 6:5.
The prepolymer polyols of the invention are characterized in that they display a glass transition temperature in the range of about -40° C. to 0° C. and an isotropization temperature below 110° C. The prepolymer polyols , in some instances , are viscous oils having low glass transition temperatures and no apparent isotropization transition.
The prepolymer polyols of the invention may be branched by the incorporation of low concentrations of acids and/or esters having a functionality of at least three. The branching increases the functionality and depresses the ability of the polyols to crystallize.
The prepolymers of the invention are suitable as precursors in polyurethane formulations, including coatings, reaction injection molding and thermoplastic polyurethane formulations.
Experimental
In demonstrating the invention a flask equipped with a nitrogen gas inlet, a mechanical stirrer and a short distillation column was charged with 100 g (0.337 mole) of dimethyl trans-4,4'-stilbene dicarboxylate, 90 g (0.45 mole) of polyether conforming to
HO--[CH.sub.2 CH.sub.2 O].sub.n --H
having a molecular weight of about 200 and an OH number of 561 and 100 ppm of titanium tetraisopropoxide. The ester interchange was carried out initially at 250° C. until a clear homogeneous solution resulted. The temperature was then reduced to 240° C. for 3 hours while methanol was being removed. The temperature was then reduced to 220° C. under reduced pressure (1 mm Hg) for about 1 hour until complete removal of methanol.
The characterization of the resulting prepolymer polyol was carried out by differential scanning calorimetry and by optically polarized microscopy. The prepolymer thus prepared had a Tg of -26° C. and a isotropization temperature of 51° C.
The molecular weight of the prepolymer was determined to be 1493.
Additional prepolymer polyols were prepared following substantially the same procedure as described above. In all the examples, the results of which are summarized in the table below, the mesogenic unit derived from dimethyl trans-4,4'-stilbene dicarboxylate, and the catalyst which was used in each case is noted in the table. The molar amounts of the mesogenic reactant and the type and molar amounts of the polyols varied as described below.
The characteristics of the resulting prepolymer are shown below.
__________________________________________________________________________ molar amount Polyether polyol PrepolymerExamplecatalyst mesogen type and molar amount MW.sup.1 properties__________________________________________________________________________1 Sn 1.25 PEO3 1.50 (2180) Tg = -11° C. Ti.sup.3 = 82° C. LC.sup.22 Sn 1.31 DiPG 1.57 (1965) not LC, solid3 Sn 0.338 TriPG 0.414 (2312) not LC, solid4 Sn 1.25 TriEG 1.50 (2060) Tg = 4° C. Ti = 102° C. LC5 Sn 1.25 TetraEG 1.56 (2324) Tg = -12° C. Ti = 103° C. LC6 Sn 0.338 TriEG/TetraEG (1342) Tg = -26° C. 50:50 0.485 (1342) Ti = 64° C. LC7 Sn 1.25 TriEG/TetraEG (2192) Tg = -10.sup.° C. 50:50 1.50 (2192) Ti = 77° C. LC8 Sn 0.74 PPG1 0.99 2266 thick oil not LC Tg = -17° C.9 Tip 2.25 PPG1 3.00 2061 Thick oil not LC Tg = -34° C.10 Sn 0.25 PPG9 0.50 (2389) oil not LC11 Tip 0.338 PEO4 0.41 2032 Tg = -17° C. Ti = 50° C. LC12 Sn 0.905 PEO4 1.09 1563 Tg = -22° C. Ti = 51° C. LC13 Sn 0.50 PEO4 0.625 (2030) Tg = -10° C. Ti = 59° C. LC__________________________________________________________________________ .sup.1 the number in parentheses is the calculated molecular weight, othe molecular weight numbers were determined from the OH number. .sup.2 LC = liquid crystalline properties .sup.3 isotropization temperature EG--ethylene glycol PG--propylene glycol PEO--polyethylene glycol PPG--polypropylene glycol PEO3--PEO having a molecular weight of 165 PEO4--PEO having a molecular weight of 200 PPG9--PPG having a molecular weight of 1000 PPG1--PPG having a molecular weight of 425 Sn = dibutyl tin dilaurate Tip = titanium tetraisopropoxide
The following is a summary of additional experiments which were carried out on branched systems. In these examples, the catalyst used was titanium tetraisopropoxide. The branching agent was 0.034 moles of trimethylbenzenetricarboxylate (TMBTC); in example 14 the branching agent was 1,3,5-TMBTC, and in Example 15 the branching agent was 1,2,4-TMBTC.
______________________________________ molar Polyether poly- amount yol type and OH prepolymerExample mesogen molar amount number properties______________________________________14 0.304 PEO4 0.47 79.2 LC under shear Tg = -23° C.15 0.304 PEO4 0.47 80.7 LC under shear Tg = -22° C.______________________________________
Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims.
|
Prepolymer polyols containing mesogenic moieties useful as reactants for the preparation of resinous materials are disclosed. Synthesized by condensing a polyether polyol with bifunctional mesogenic diacids, or diesters, the compounds of the invention are characterized by their reasonably low melt temperature which renders them suitable as additive materials in polymeric molding compositions and as precursors for the preparation of resinous materials.
The liquid crystalline properties of the prepolymers of the invention were found to depend on the type and molecular weight of the glycols and on the molar ratio between the glycols and the mesogenic reactant.
| 2
|
REFERENCES TO CO-PENDING APPLICATIONS
[0001] This application is a continuation-in-part of co-pending application Ser. No. 08/697,453 filed Aug. 23, 1996 entitled PRE-MOUNTED STENT DELIVERY DEVICE WITH INFLATABLE TUBE COMPONENT, herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to an assembly method for delivering and deploying an inflation expandable stent particularly within a lumen of a body vessel. More specifically, this invention relates to the provision of a securement component positioned over the inner catheter, and beneath a balloon and a loaded stent, to maintain the stent on the catheter assembly during delivery to a stent deployment site.
[0004] 2. Description of Relevant Art
[0005] Stents and stent delivery assemblies are utilized in a number of medical procedures and situations, and as such their structure and function are well-known. A stent is a general cylindrical prosthesis introduced via a catheter into a lumen of a body vessel in a configuration having a generally reduced diameter and then expanded to the diameter of the vessel. In its expanded configuration, the stent supports and reinforces the vessel walls while maintaining the vessel in an open, unobstructed condition.
[0006] Both self-expanding and inflation expandable stents are well-known and widely available. Self-expanding stents must be maintained under positive external pressure in order to maintain their reduced diameter configuration during delivery of the stent to its deployment site. Inflation expandable stents (also known as balloon expandable stents) are crimped to their reduced diameter about the delivery catheter, positioned at the deployment site, and then expanded to the vessel by diameter by fluid inflation of the balloon positioned between the stent and the delivery catheter. The present invention is particularly concerned with enhanced stent securement and safer stent loading in the delivery and deployment of balloon expandable stents.
[0007] In angioplasty procedure, there may be restenosis of the artery, which either necessitates another angioplasty procedure, a surgical bi-pass procedure, or some method of repairing or strengthening the area. To prevent restenosis and strengthen the area, a physician can implant an intravascular prosthesis for maintaining vascular patency, i.e. a stent, inside the artery at the lesion. The stent is expanded to a larger diameter for placement in the vasculature, often by the balloon portion of the catheter. Stents delivered to a restricted coronary artery, expanded to a larger diameter as by a balloon catheter, and left in place in the artery at the site of a dilated lesion are shown in U.S. Pat. No. 4,740,207 to Kreamer; U.S. Pat. No. 5,007,926 to Derbyshire; U.S. Pat. No. 4,733,665 to Palmaz; U.S. Pat. No. 5,026,377 to Burton et al.; U.S. Pat. No. 5,158,548 to Lau et al.; U.S. Pat. No. 5,242,399 to Lau et al.; U.S. Pat. No. 5,344,426 to Lau et al.; U.S. Pat. No. 5,415,664 to Pinchuck; U.S. Pat. No. 5,453,090 to Martinez et al.; U.S. Pat. No. 4,950,227 to Savin; U.S. Pat. No. 5,403,341 to Solar; U.S. Pat. No. 5,108,416 to Ryan et al.; and European Patent Application No. 707837A1 to Scheiban, all of which are incorporated herein by reference. A stent particularly preferred for use with this invention is described in PCT Application No. 96/03092-A1, published Feb. 8, 1996, the content of which is incorporated herein by reference.
[0008] In advancing a balloon expandable stent through a body vessel to the deployment site, there are a number of important considerations. The stent must be able to securely maintain its axial position on the delivery catheter. The stent, particularly its distal and proximal ends, are sometimes protected to prevent distortion of the stent, and minimize trauma to the vessel walls. Balloon expandable stent delivery and deployment assemblies are known which utilize restraining means that overlay the stent during delivery. U.S. Pat. No. 4,950,227 to Savin et al., relates to a balloon expandable stent delivery system in which a sleeve overlaps the distal or proximal margin (or both) of the stent during delivery. During inflation of the stent at the deployment site, the stent margins are freed of the protective sleeve(s) and the sleeves then collapse toward the delivery catheter for removal. A number of balloon expandable stent delivery and deployment assemblies do not use overlaying restraining members, such as the Savin sleeves, to position the stent for delivery. European Patent Application No. EP 055 3960A1 to Lau et al., uses an elastic sheath interspaced between the balloon and the stent. The sheath is said to act as a barrier to protect the balloon from the stent, allow uniform stent expansion, decrease balloon deflation time, prevent undesirable balloon flattening upon deflation and provide a friction substrate for the stent. The Lau sheath can be positioned on the inside or outside of the balloon. U.S. Pat. No. 5,409,495 to Osborne, similarly uses an elastic sleeve or sheath surrounding and in contact with the balloon for controlling the balloon radial expansion. In addition, Osborne is said to use restraining bands or a pair of balloons to achieve controllable stent expansion characteristics. U.S. Pat. No. 5,403,341 to Solar, relates to stent delivery and deployment assembly which uses a retaining sheath positioned about opposite ends of the compressed state. The retaining sheaths of Solar are adapted to tear under pressure as the stent is radially expanded, thus releasing the stent for engagement with the sheaths. U.S. Pat. No. 5,108,416 to Ryan et al. describes a stent introducer system which uses one or two flexible end caps and annular socket surrounding the balloon to position the stent during introduction to the deployment site. The content of all of these patents is incorporated herein by reference.
[0009] In positioning a balloon expandable stent on the delivery catheter over the fluid expandable balloon, the stent must be smoothly and evenly crimped to closely conform to the overall profile of the catheter and the unexpanded balloon. It has been noted that, due to physical properties of the material used in manufacturing the stent (stainless steel, tantalum, platinum or platinum alloys, or shape memory alloys such as Nitinol™) there is a certain amount of “recoil” of the stent despite the most careful and firm crimping. That is the stent evidences a tendency to slightly open up from the fully crimped position and once the crimping force has been released. For example, in the typical stent delivery and deployment assembly, if the stent has been fully crimped to a diameter of approximately 0.0035″, the stent has been observed to open up or recoil to approximately 0.0037″. This phenomenon has been characterized as “recoil crimping”. Due to recoil crimping to this slightly enlarged diameter, it can be understood that the stent tends to evidence a certain amount of looseness from its desired close adherence to the overall profile of the underlying catheter and balloon. That is, the stent tends to have a perceptible relatively slack fit in its mounted and crimped position. During delivery, the stent can thus tend to slip and dislocate from its desired position on the catheter or even become separate from the catheter, requiring further intervention by the physician.
[0010] Further, there is a possibility of damaging the balloon during the stent crimping as a result of pinching the balloon material between the metal stent and any metal (or protruding object) on the inner guide lumen (e.g. marker bands).
[0011] According to the present invention, a securement means such as a corrugated (accordion-type) tube is secured over the Inner catheter beneath the balloon to compensate for the undesired looseness or slack that due to recoil crimping and to aid in securing the stent to the balloon, as well as protecting the balloon material from being sandwiched between the stent and any metal or protruding item which may be mounted on the inner shaft/guide wire lumen, for delivery of the stent. The corrugated tube provides additional volume for improved stent securement, i.e. more surface area to crimp onto, and also maintains flexibility. In addition, when metal marker bands are employed on the inner catheter, the tubing aids in preventing damage to the balloon during crimping/loading of the stent. The tubing, which may be inflatable, compensates for the perceptible looseness due to recoil crimping and secures the stent during tracking and delivery and provides a good friction fit to the stent and insures good contact between the stent and underlying balloon and catheter, instead of merely relying on the bulk of the flaccid balloon over the underlying catheter to hold the stent on. According to the present invention, the tubing component will compensate for slackness in the fit of the stent due to recoil crimping.
[0012] According to another embodiment of the present invention, the securement means is an expandable tube component positioned under the expandable balloon to compensate for this undesired looseness or slack fit due to recoil crimping and to aid in securing the stent to the balloon and the catheter for delivery. The expandable tube component and the expandable balloon are each provided with separate, individually controllable fluid inflation sources. Once the stent has been fully crimped to conform to the overall profile of the catheter, the expandable balloon, and the underlying expandable tube component, the tube component is inflated. The tube component is inflated to at least the limits of the elastic deformation of the fully crimped stent. It is desirable to slightly further inflate the tube component to a pressure at which the fully crimped stent just begins to plastically deform. That is, the tube component many be inflated to a point at which the stent is just barely beginning to provide resistance to the expansion of the tube component, which is also characterized as a point at which the stent just barely begins to expand beyond the crimped position (taking into consideration the recoil crimping phenomenon). The desired pressure to which the tube component is inflated is characterized as the “securement pressure”. The application of securement pressure to the tube component compensates for the perceptible looseness due to recoil crimping and secures the stent during tracking and delivery. The application of securement pressure to the tube component provides a good friction fit to the stent and ensures good contact between the stent and the underlying balloon, “securement pressurized” tube component and catheter. The desired diameter of the stent upon the application of securement pressure to the tube component is characterized as the “delivery diameter”, because in this condition the stent can safely, reliably and securely be delivered to the pre-selected position within a body vessel. Instead of merely crimping the stent onto the balloon and the underlying catheter and relying on the bulk of the flaccid balloon to hold the stent on, according to the present invention, the expandable tube component will compensate for slackness in the fit of the stent due to recoil crimping. Prior to inflation of the tube component to the securement pressure, the physician preparing the assembly may manually sense a looseness of the stent in its position. When the tube component has been inflated to the necessary securement pressure, the physician will manually sense that the stent is securely retained or “stuck” in position. The expandable tube component is designed and constructed to be expandable to no more than is necessary to compensate for recoil crimping and is incapable of overexpanding to provide the pressure needed to fully expand the stent to its deployment position.
[0013] There are a number of descriptions of catheters which use a pair of coaxial, at least partially coextensive balloons. U.S. Pat. No. 5,512,051 to Want et al., describes a slip layered balloon made of a plurality of layers with a low friction substance between the layers. During expansion the layers are able to slide relative to each other softening the balloon while maintaining its strength. U.S. Pat. No. 5,447,497 to Sogard et al., relates to s a dual layered balloon, in which one balloon is compliant and the other is non-compliant, so that the balloon assembly has a non-linear compliance curve. U.S. Pat. No. 5,358,487 to Miller, describes a balloon catheter having an outer balloon surrounding an inner balloon. The inner balloon has a maximum inflation diameter less than that of the outer balloon, so that, upon inflation, the inner balloon bursts at a certain diameter, allowing the outer balloon to be further expanded. U.S. Pat. No. 5,290,306 to Totta et al., relates to a balloon catheter with an outer elastomeric sleeve to provide the balloon with pin hole and abrasion resistance. U.S. Pat. No. 5,049,132 to Shaffer et al., describes a first balloon and a second balloon, each having separate inflation lumens, the second balloon having apertures for controlled administration of a medication therethrough. U.S. Pat. Nos. 4,608,984 and 4,338,942 to Fogarty, each relate to a catheter with an inner non-elastic balloon and an outer elastic balloon. In each patent, the outer balloon aids in collapse and retraction of the inner balloon. U.S. Pat. No. 4,328,056 to Snooks, describes a method of making a double cuffed endotracheal tube component. However, none of these references show, suggest or render obvious an inner balloon, in conjunction with an outer deployment inflatable balloon, to provide securement pressure to a compressed stent during delivery to a site within a body vessel.
[0014] The art referred to and/or described above is not intended to constitute an admission that any patent, publication or other information referred to herein is “prior art” with respect to this invention. In addition, this section should not be construed to mean that a search has been made or that no other pertinent information as defined in 37 C.F.R. §1.56(a) exists.
SUMMARY OF THE INVENTION
[0015] The present invention is an assembly for delivery and deployment of an inflation expandable stent within a vessel. The assembly comprises a catheter, an expandable balloon mounted on the catheter, a stent securement means mounted on the catheter beneath or within the balloon, and a stent mounted on the balloon. The catheter has proximal and distal ends. The stent is inflation expandable from a delivery diameter to a deployment diameter. The delivery diameter is reduced from the deployment diameter for conforming the stent to the catheter. The stent, in its delivery diameter, is coaxially mounted on the catheter near the catheter distal end. The expandable balloon is coaxially mounted on the catheter axially within the stent. The balloon is designed and adapted for expansion of the stent from the delivery diameter to the deployment diameter upon application of fluid deployment pressure to the balloon. The securement means may be corrugated tubing mounted and adhered coaxially onto the catheter and situated between the balloon and the catheter itself. Alternatively, the securement means may be an expandable tube component mounted on the catheter. The expandable tube component is coaxially mounted on the catheter, axially within the expandable balloon. The expandable tube component is designed and adapted for fluid expansion to provide a securement pressure to the stent in the delivery diameter to maintain the stent in position on the catheter during delivery to the deployment site. The expandable tube component is sized and constructed to be fluid expandable to no more than the delivery diameter. The expandable tube component or corrugated tube is essentially equal in length to the stent and the stent is positioned on the assembly essentially coextensive with the tube component. When the stent is crimped and loaded onto the balloon, the balloon is situated therefore between the stent and the securement means. The securement means is preferably essentially equal to the length of the stent and the stent is positioned on the assembly essentially co-extensive with the tube component. The present invention is particularly directed to improved arrangements for releasably attaching the stent to the catheter to facilitate delivery thereof. Generally, the stent is held in place upon the catheter by means of an enlarged body carried by the catheter shaft within the balloon to which the stent and the balloon are fitted, as by crimping. The securement means on the catheter effectively holds the stent in place, takes up the slack due to recoil and protects the balloon material from being damaged during crimping.
BRIEF DESCRIPTION OF THE FIGURES
[0016] [0016]FIG. 1 is a side profile section showing a balloon expandable stent delivery and deployment assembly, with the stent crimped to delivery diameter onto the balloon, the underlying corrugated tube component and the catheter.
[0017] [0017]FIG. 2 is a side profile section, similar to FIG. 1, with the balloon and the stent fully inflated to deployment diameter.
[0018] [0018]FIG. 3 is a perspective view of the corrugated tubing of the present invention.
[0019] FIGS. 4 - 6 are side profile sections showing alternative embodiments of balloon expandable stent delivery and deployment assemblies, having the tubing component formed in a plurality of sections.
[0020] FIGS. 7 - 8 are side profile sections showing alternative embodiments of the balloon expandable stent delivery and deployment assemblies, the tube component inflatable to add securement pressure.
[0021] [0021]FIG. 9 is a side profile section showing a balloon expandable stent delivery and deployment assembly, with the stent crimped to delivery diameter onto the balloon, the underlying tube component and the catheter, and also having containment sleeves covering the ends of the stent.
[0022] [0022]FIG. 10 is a side profile section showing a balloon expandable stent delivery and deployment assembly, with the stent crimped to delivery diameter onto the balloon, the underlying tube component and the catheter, and also having a pull-back wire attached to the tube component.
[0023] [0023]FIG. 11 is a side profile section of an alternative embodiment showing a balloon expandable stent delivery and deployment assembly, with the stent crimped to delivery diameter onto the balloon, the underlying inflating tube component and the catheter and with the inflating tube component inflated to securement pressure.
[0024] [0024]FIG. 12 is a side profile section, similar to FIG. 11, with the balloon and the stent fully inflated to deployment diameter.
[0025] [0025]FIG. 13 is a side profile section showing an alternative embodiment of a balloon expandable stent delivery and deployment assembly, having a tube component formed in several sections.
[0026] [0026]FIGS. 14, 15 and 16 are cross-sectional views taken along lines 44 , 55 and 6 - 6 of FIG. 13, respectively.
DETAILED DESCRIPTION OF THE INVENTION
[0027] [0027]FIGS. 1 and 2 illustrate a side profile section showing an inflation expandable stent delivery and deployment assembly, generally designated 10 . Assembly 10 includes a catheter comprised of inner shaft 12 and outer shaft 13 of the coaxial type and an optional retractable delivery shaft 11 (typically called a guide catheter, shown retracted in FIG. 2), an inflation expandable balloon 14 , a corrugated/ribbed stent securement device 16 , optional marker bands 17 and an inflation expandable stent 18 . Any conventional type of catheter may be used, such as a catheter of the type generally used for PTA or PTCA angioplasty procedures, for prostate therapy, and TTS endoscopic catheters for gastrointestinal use. However, coaxial types as show are most preferred. The particular catheters 12 and 13 shown are formed of a biocompatible and hydrophilic compatible material, such as a lubricous polyimide or poly ethylene. Other suitable materials for the catheters 12 and 13 include nylons, urethanes, and polypropylene materials compatible with coatings such as silicone and/or hydrophilic coatings. In addition to hydrophilic compatible materials, any biocompatible material may be used. For example, polyethylene or polypropylene can be coated with a hydrophilic material to render them hydrophilic compatible. Suitable catheters for use according to the present invention include a number of catheters available from SciMed Life Systems, Inc., Maple Grove, Minn., the assignee of the present invention, such as BANDIT™, COBRA™, VIVA™, VIVA PRIMO™, MAXXUM™, MAXXUM ENERGY™ and RANGER™ catheters.
[0028] Securement device 16 is fixed at its distal and/or proximal ends to inner shaft 12 at a position to be encompassed within the distal and proximal ends of the outer balloon 14 . According to art-recognized convention, the length L-B of the balloon 14 is defined as the length of the body portion of the balloon 14 , excluding the terminal cone sections 20 . As seen in FIG. 2, the body portion of the balloon 14 is generally cylindrical when in its deployed or inflated condition. Securement device/tube component 16 is illustrated as having terminal sections 21 , 22 . It is to be understood that, according to the present invention, either of the terminal sections 21 , 22 may be relatively cone shaped, relatively vertical, relatively flat or of any other configuration known to those of skill in this art. A preferred length L-T of the tubing 16 is illustrated in FIGS. 1 and 2 as substantially equal to the length L-B of balloon 14 , and substantially equal to the length L-S of stent 1 S. However, according to the present invention, stent 18 should be supported by the underlying tube component 16 for a length sufficient to permit accomplishment of the stated purpose of the tube component 16 , to provide a superior securement and protective surface for stent 18 to maintain stent 18 in position with assembly 10 and to protect the balloon material during loading/crimping. It is also within the present invention for the tube component 16 to be slightly shorter than stent 18 , for example, the distal end 19 of stent 18 may extend distally beyond the distal end 22 of tube component 16 (not shown), so that the distal end 19 of stent 18 can be crimped over the distal end 22 of tube component 16 to prevent the distal end 19 of stent 18 from catching and tending to snag or further open as it is maneuvered within a body vessel. As has been explained above, tube component 16 is designed and constructed to have enough flexibility and have enough volume to no more than is necessary to compensate for recoil crimping of stent 18 and to closely accommodate (or even slightly over stress) the delivery diameter of stent 18 , taking into consideration the thickness of the intervening uninflated balloon 14 . Typically, the tube component 16 will have a consistent frequency of ribs, but may also vary by having intermittent groups of ribs along the tubing.
[0029] The balloon and the crimped stent slightly conform to the undulations of the tube component for greater securement, but this conformation is not illustrated.
[0030] Tube component 16 may be formed from a thermoplastic material, preferably a low modulus polymer, such as Surlyn™, Pebax and urethane. The device such as polypropylene, low density polyethylene (LDPE), high density polyethylene (HDPE), ethylene vinyl acetate (EVA), nylon, polyester and polyethylene terephthalate (“PET”), may be prepared through free blowing in a mold or inside a coil. Tubing is extruded with relatively thin walls and then free-blown in a mold, coil or other fixture to form the ribs/corrugation.
[0031] A balloon 14 for use according to the present invention may be any conventional balloon for catheter delivery, such as a balloon of the type generally used for PTA and PTCA procedures. Typically, balloon 14 is fixed at its distal end to inner shaft 12 near the catheter distal end and at its proximal end to inner shaft 12 , near the distal end of the outer shaft 13 . Balloon 14 is inflatable through an inflation conduit 23 , i.e., the space between coaxial inner shaft 13 and outer shaft 13 of the catheter. The distal and proximal ends of balloon 14 are shown in FIGS. 1 and 2 positioned exterior the distal and proximal ends of tube component 16 , respectively, and of a length L-B generally equal to the length L-T of the tube component 16 . To be compatible with the tube component 16 illustrated in FIGS. 1 and 2 and described above, balloon 14 is inflatable at deployment to about the diameter of the body vessel in which the stent 18 is to be deployed. Balloon 14 may be formed of a compliant or non-compliant material, such as polyethylene or any standard balloon material. Compliant materials include low pressure, relatively soft or flexible polymeric materials, such as thermoplastic polymers, thermoplastic elastomers, polyethylene (high density, low density, intermediate density, linear low density), various co-polymers and blends of polyethylene, ionomers, polyesters, polyurethanes, polycarbonates, polyamides, poly-vinyl chloride, acrylonitrile-butadiene-styrene copolymers, polyether-polyester copolymers, and polyetherpolyamide copolymers. Suitable materials include a copolymer polyolefin material available from E.I. DuPont de Nemours and Co. (Wilmington, Delaware), under the trade name Surlyn™ Ionomer and a polyether block amide available under the trade name PEBAX™. Non-compliant materials include relatively rigid stiff high pressure polymeric materials, such as thermoplastic polymers and thermoset polymeric materials, poly(ethylene terephthalate) (commonly referred to as PET), polyimide, thermoplastic polyimide, polyamides, polyesters, polycarbonates, polyphenylene sulfides, polypropylene and rigid polyurethanes, or combinations thereof. The balloon 14 typically has a wall thickness of about 0.0007-0.004″ for example.
[0032] A stent for use according to the present invention may be any conventional type of balloon expandable stent, including stents of the type used for PTA and PTCA angioplasty procedures, for prostate therapy, and TTS endoscopic catheters for gastrointestinal use. Suitable stent material is biocompatible stainless steel in the form of sheet metal, tube component wire or Nitinol. A preferred stent is described in PCT Application No. 960 3072 A1, published Feb. 8, 1996, the content of which is incorporated herein by reference. All such stents are well-known in this art generally and additional examples are described in U.S. Pat. No. 5,507,768 to Lau et al.; in U.S. Pat. No. 5,458,615 to Klemm et al.; in U.S. Pat. No. 5,226,899 to Scheiban; in U.S. Pat. No. 4,875,480 to Imbert; in U.S. Pat. No. 4,848,343 to Wallsten et al.; and in U.S. Pat. No. 4,733,665 to Palmaz. Stent 18 as shown in FIGS. 1 and 2 is positioned on balloon 14 , which is over the underlying tube component 16 , at the distal end of the catheter. The length L-S of stent 18 is shown as essentially equal or slightly smaller than the length L-T of tube component 16 and is positioned on assembly 10 to be coextensive with tube component 16 . In this position, stent 18 is shown in FIG. 1 crimped to its delivery diameter D 1 , which is about 0.035-0.45″ for example.
[0033] As discussed above, despite the most careful and firm crimping of stent 18 to closely conform to the overall profile of the catheter unexpanded balloon 14 and underlying tube component 16 , there is a certain amount of “recoil” of stent 18 or a tendency of stent 18 to slightly open from a desired hypothetical minimum crimped diameter. The actual minimum diameter achievable for fully crimped stent 18 on assembly 10 is referred to as stent 18 delivery diameter D 1 . This tendency of stent 18 to open or recoil slightly when crimped on assembly 10 has been characterized as “recoil crimping”. In FIG. 1, tube component 16 is shown at a diameter which is generally sufficient to compensate for any slack or looseness between crimped stent 18 and the overall profile of the catheter, the unexpanded balloon 14 and the underlying tube component 16 due to recoil crimping.
[0034] [0034]FIG. 2 illustrates a side profile section showing a stent delivery and deployment assembly 10 of this invention with balloon 14 fluid inflated to its fully expanded position. As a result of the fluid inflation of the balloon 14 , stent 18 has also been fully expanded to its deployment diameter D 2 in which it can be deployed against the walls of a body vessel in which it is situated.
[0035] [0035]FIG. 3 illustrates the preferred configuration of the tube component 16 . The tube component has a plurality of ribs 30 and is configured in a corrugated or accordion fashion. The ends of the tube component 16 , 22 and 21 , are substantially rib-free so as to provide a flat surface to receive an adhesive and thereby bond to the inner shaft 12 . Preferable adhesives include cyanocrylates such as Loctite 4061/4011 or urethanes, such as H.B. Fuller 3507/3506. The tube component may also be heat bonded to the inner shaft. The ribs may vary in frequency and spacing.
[0036] Tube component 16 may have different configurations in other embodiments, as shown in FIGS. 4 - 6 . The tube component 16 may be comprised of more that one piece of corrugated tubing (FIG. 4), a smaller single piece (FIG. 5) or one single piece of tubing sectioned into a plurality of ribbed sections, wherein the tubing is adhered to the inner shaft 12 in more than two locations (FIG. 6).
[0037] [0037]FIG. 4 shows two pieces of tubing component 16 a , 16 b . Both pieces are adhered to inner shaft 12 at adhesion points 32 . FIG. 5 discloses an embodiment which comprises one smaller piece of tube component 16 which is adhered to inner shaft 12 at adhesion points 32 . FIG. 6 discloses an embodiment which comprises one tube component 16 which has interrupted ribbed sections 34 adhered to the inner shaft 12 .
[0038] [0038]FIGS. 7 and 8 illustrate an alternative embodiment in which the tubing component is inflatable to increase the securement pressure on the inside of balloon 14 when the stent is crimped onto the balloon so as to negated additional recoiling. The full expansion of the tube component 16 should only be slightly greater than the diameter of the inside of the balloon 14 when the stent 18 is fully crimped onto the balloon 14 .
[0039] In FIG. 7, the inflating fluid comes through the guide wire lumen 12 under pressure from the proximal end or the distal end of the guide wire lumen 12 , preferably via a syringe, and fills the tubing component 16 through a one-way valve 47 (preferably resisting up to about 4 atm) in the inner catheter 12 .
[0040] In FIG. 8, the tubing component 16 is inflated via an additional lumen 42 which extends from the proximal end of the catheter along the guide wire lumen 40 , much the same as any inflating lumen incorporated to inflate a balloon.
[0041] In an alternative embodiment, as shown in FIG. 9, socks or sleeves 51 may be incorporated to stretch over the ends of the stent to prevent snagging and to secure the stent onto the balloon. Such sleeves are demonstrated in U.S. application Ser. No. 08/702,149, filed Aug. 23, 1996, and Ser. No. 08/701,979, filed Aug. 23, 1996, which are incorporated in their entirety herein by reference.
[0042] In still another embodiment, as shown in FIG. 10, the tubing component 16 is slidable axially along the inner shaft 12 and is connected to a retracting wire 50 such that the tubing component may be retracted into the outer shaft 13 after the balloon has been inflated to reduce the profile of the balloon 14 when the catheter is removed. The tubing component, since it is not adhered to the inner shaft 12 in this embodiment, should fit tightly enough on the inner shaft to stay in place, but not too tightly so that it may be retracted by pulling on the retracting wire 50 .
[0043] The method of using the stent delivery and deployment assembly 10 of this invention, as shown in FIGS. 1 and 2, is described as follows. The assembly 10 is constructed as described above. Stent 18 is compressed or crimped onto balloon 14 , tube component 16 and the catheter to a delivery diameter D 1 . This crimping can be done manually or with the aid of tooling specifically designed for the purpose either by the physician or the manufacturer. In the crimped position, stent 18 closely conforms to the overall profile of balloon 14 , tube component 16 and the catheter except for the slight slack or looseness due to recoil crimping. Tube component 16 is flexible enough to slightly collapse during crimping and rebound to the extent necessary to compensate for the slack or looseness due to recoil crimping, thus securing the stent. As a result, the stent does not move out of its position on the catheter during delivery or become separated from the catheter within a body vessel. The catheter distal end is delivered by standard techniques to the deployment site within the body vessel of interest. At this point, stent 18 is positioned as required by the physician and balloon 14 is fluid inflated by standard technique to expand stent 18 to its deployment diameter D 2 . During this expansion, stent 18 is expanded to fill the body vessel. Following deployment of stent 18 , balloon 14 is deflated and the assembly is retracted proximally and withdrawn from the body. If required by the procedure, the site of entry to the body is appropriately closed.
[0044] The tube component provided by this invention increases stent securement force by increasing the frictional force between the tube component, the balloon wall and the internal diameter of the stent in its reduced crimped delivery diameter. The tube component is more flexible than a solid sheath under the expandable balloon, and thus the entire assembly has greater flexibility. This invention has particular advantages for assemblies in which the stent is provided for use as pre-crimped to the balloon and underlying catheter, by increasing the shelf life of the pre-crimped assembly. The tube component also protects the balloon material during crimping by acting as a buffer between the balloon material and whatever may be mounted on the inner shaft, such as marker bands 17 . The features and principles described for this invention are suitable for use with fixed wire, over-the-wire and single operator exchange assemblies.
[0045] Another embodiment of the present invention is shown in FIGS. 11 and 12 which illustrate a side profile section showing an inflation expandable stent delivery and deployment assembly generally designated 110 . Assembly 110 includes a catheter comprised of inner shafts 112 and 113 and an outer shaft 115 of the coaxial type, an inflation expandable balloon 114 , an inflation tube component 116 such as an inner balloon and inflation expandable stent 118 . Any conventional type of catheter may be used, such as a catheter of the type generally used for PTA or PTCA angioplasty procedures, for prostate therapy, and TTS endoscopic catheters for gastrointestinal use. However, coaxial types as shown are most preferred. The particular catheter 112 shown is formed of a biocompatible and hydrophilic compatible material, such as a lubricous polyimide or polyethylene. Other suitable materials for the catheter 112 include nylons, urethanes, and polypropylene materials compatible with coatings such as silicone and/or hydrophilic coatings. In addition to hydrophilic compatible materials, any biocompatible material may be used. For example, polyethylene or polypropylene can be coated with a hydrophilic material to render them hydrophilic compatible. suitable catheters for use according to the present invention include a number of catheters available from Scimed Life Systems, Inc., Maple Grove, Minn., the assignee of the present invention, such as BANDIT™, COBRA™, VIVA™, and VIVA PRIMO™ catheters.
[0046] Inflatable tube component 116 is fixed at its distal and proximal end to inner shaft 112 and at its proximal end to inner shaft 113 at a position to be encompassed within the distal and proximal ends of the outer balloon 114 . According to art-recognized convention, the length L-B of the balloon 114 is defined as the length of the body portion of the balloon 114 , excluding the terminal cone sections 120 . As seen in FIG. 12, the body portion of the balloon 114 is generally cylindrical when in its deployed or inflated condition. Tube component 116 is illustrated as having terminal sections 122 which are more relatively vertical than the cone sections 120 illustrated for the balloon 114 . However, it is to be understood that, according to the present invention, either of the terminal sections 120 , 122 may be-relatively cone shaped, relatively vertical or of any other configuration known to those of skill in this art. A preferred length L-T of the tube component 116 is illustrated in FIGS. 11 and 12 as substantially equal to the length L-B of balloon 114 , and substantially equal to the length L-S of stent 112 . However, according to the present invention, stent 112 should be supported by the underlying tube component 116 for a length sufficient to permit accomplishment of the stated purpose of the tube component 116 , when inflated, to provide securement pressure for stent 112 to maintain stent 112 in position with assembly 110 during delivery. It is also within the present invention for tube component 116 to be slightly shorter than stent 112 , for example, the distal end 119 of stent 112 may extend distally beyond the distal end 121 of tube component 116 (not shown), so that the distal end 119 of stent 121 can be crimped over the distal end 121 of tube component 116 to prevent the distal end 119 of stent 112 from catching and tending to further open as it is maneuvered within a body vessel. As has been explained above, tube component 116 is designed and constructed to be inflatable to no more than is necessary to compensate for recoil crimping of stent 112 and to closely accommodate (or even slightly over-stress) the delivery diameter of stent 112 , taking into consideration the thickness of the intervening uninflated balloon 114 . Tube component 116 is inflated through the opening(s) 117 of inner shaft 112 . Typically, tube component 116 will have a wall thickness of about 0.0002-0.0007 inch and will be inflatable to no more than about 0.035.-0.045 inches.
[0047] Inflating tube component 116 may be formed of either compliant or non-compliant balloon materials. Compliant materials include low pressure, relatively soft or flexible polymeric materials, such as thermoplastic polymers, thermoplastic elastomers, polyethylene (high density, low density, intermediate density, linear low density), various co-polymers and blends of polyethylene, ionomers, polyesters, polyurethanes, polycarbonates, polyamides, poly-vinyl chloride, acrylonitrile-butadiene-styrene copolymers, polyether-polyester copolymers, and polyetherpolyamide copolymers. Suitable materials include a copolymer polyolefin material available from E.I. DuPont de Nemours and Co. (Wilmington, Del.), under the trade name Surlyn™ Ionomer and a polyether block amide available under the trade name PEBAX™. Non-compliant materials include relatively rigid of stiff high pressure polymeric materials, such as thermoplastic polymers and thermoset polymeric materials, poly(ethylene terephthalate) (commonly referred to as PET), polyimide, thermoplastic polyimide, polyamides, polyesters, polycarbonates, polyphenylene sulfides, polypropylene and rigid polyurethanes.
[0048] A balloon 114 for use according to the present invention may be any conventional balloon for catheter delivery, such as a balloon of the type generally used for PTA and PTCA procedures. Typically, balloon 114 is fixed at its distal end to inner shaft 112 near the catheter distal end and at its proximal end to outer shaft 115 . Balloon 114 is larger in diameter than tube component 116 , because balloon 114 must be able to expand to a larger diameter than tube component 116 . Balloon 114 is inflatable through an inflation conduit 123 , i.e., the space between coaxial inner shaft 113 and outer shaft 115 of the catheter. The distal and proximal ends of balloon 114 are shown in FIGS. 11 and 12 positioned exterior to the distal and proximal ends of tube component 116 , respectively, and of a length L-B generally equal to the length L-T of the tube component 116 . To be compatible with tube component 116 illustrated in FIGS. 11 and 12 and described above, balloon 114 is inflatable at deployment to about the diameter of the body vessel in which the stent 118 is to be deployed. Balloon 114 may be formed of a compliant or non-compliant material, of the types of compliant materials described herein above, such as polyethylene or any standard balloon material. Balloon 114 typically has a wall thickness of about 0.0007-0.004 inch for example.
[0049] A stent for use according to the present invention may be any conventional type of balloon expandable stent, including stents of the type used for PTA and PTCA angioplasty procedures, for prostate therapy, and TTS endoscopic catheters for gastrointestinal use. Suitable stent material is biocompatible stainless steel in the form of sheet metal, tube component wire or Nitinol. A preferred stent is described in PCT Application No. 960 3072 A1, published Feb. 8, 1996, the content of which is incorporated herein by reference. All such stents are well known in this art generally and additional examples are described in U.S. Pat. No. 5,507,768 to Lau et al.; in U.S. Pat. No. 5,458,615 to Klemm et al; in U.S. Pat. No. 5,226,889 to Sheiban; in U.S. Pat. No. 4,875,480 to Imbert; in U.S. Pat. No. 4,848,343 to Wallsten et al., and in U.S. Pat. No. 4,733,665 to Palmaz. Stent 118 as shown in FIGS. 11 and 12 is positioned on balloon 114 , the underlying inflatable tube component 116 and the distal end of the catheter. The length L-S of stent 118 is shown as essentially equal or slightly smaller than the length L-T of tube component 116 and is positioned on assembly 110 to be co-extensive with tube component 116 . In this position, stent 118 is shown in FIG. 11 crimped to its delivery diameter D 1 , which is about 0.035-0.045 inch for example.
[0050] As discussed above, despite the most careful and firm crimping of stent 118 to closely conform to the overall profile of the catheter unexpanded balloon 114 and underlying inflatable tube component 116 , there is a certain amount of “recoil” of stent 118 or a tendency of stent 118 to slightly open from a desired hypothetical minimum crimped diameter. The actual minimum diameter achievable for fully crimped stent 118 on assembly 110 is referred to as the stent 118 delivery diameter D 1 . This tendency of stent 118 to open or recoil slightly when crimped on assembly 110 has been characterized as “recoil crimping”. In FIG. 11, inflatable tube component 116 is shown inflated to a diameter which is generally sufficient to compensate for any slack or looseness between crimped stent 118 and the overall profile of the catheter, the unexpanded balloon 114 and the underlying inflatable tube component 116 due to recoil crimping.
[0051] [0051]FIG. 12 illustrates a side profile section showing a stent delivery and deployment assembly 110 of this invention with balloon 114 fluid inflated to its fully expanded position. As a result of the fluid inflation of the balloon 114 , stent 118 has also been fully expanded to its deployment diameter D 2 in which it can be deployed against the walls of a body vessel in which it is situated.
[0052] Tube component 116 may have a shape other than the cylindrical shape described and illustrated with regard to the embodiment shown in FIGS. 11 and 12. Further, the tube component may be comprised of more than one separately inflatable pouch. For example, as illustrated with regard to FIG. 13, the tube component of an alternative stent delivery and deployment assembly generally designated 130 can be comprised of three separately inflatable pouches 136 , 138 , 140 . The pouches 136 , 138 , 140 are each separately inflatable through their respective inflation conduits 137 , 139 , 141 , and each of the pouches 136 , 138 , 140 can be inflatable to a different extent. The conduits are formed in the wall of shaft 132 as can be seen in FIGS. 14 - 16 . The stent delivery and deployment assembly 130 of FIG. 13 is also comprised of a catheter having inner shaft 132 and outer shaft 135 , a balloon 134 , with its balloon inflation conduit 139 and the balloon terminal cone sections 144 , and a stent 142 . As has been explained above with reference to FIGS. 11 and 12, stent 142 is crimped to closely conform to the overall profile of the catheter the unexpanded balloon 134 and the underlying inflatable pouches 136 , 138 140 . Even with the most careful and firm crimping, there is a certain amount of “recoil” of the stent 142 or a tendency of stent 142 to slightly open from a desired hypothetical minimum diameter. In FIG. 13, the first 136 and third 140 pouches are inflated to a slightly larger size than the second pouch 138 . As discussed above, the inflation of the pouches 136 , 138 , 140 to this configuration is generally sufficient to compensate for any slack or looseness between the crimped stent 142 and the overall profile of the catheter, the unexpanded balloon 134 and the underlying inflatable pouches 136 , 138 , 140 due to recoil crimping. Once pouches 136 , 138 140 have been inflated to the configuration shown in FIG. 13, stent 142 is firmly secured against axial movement with regard to assembly 130 . The distal 146 and proximal 148 ends of stent 142 are protected from any possible unwanted contact with vessel walls during maneuvering, which helps to protect the vessel walls from abrasion and also helps to protect the ends 146 , 148 of stent 142 from distortion. Additionally, stent 142 may be of a length such that it fits over pouch 140 and pouch 136 as well as over pouch 138 .
[0053] The method of using the stent delivery and deployment assembly 110 of this invention, as shown in FIGS. 11 and 12, is described as follows. The assembly 110 is constructed as described above. Stent 118 is compressed or crimped onto balloon 114 , inflatable tube component 116 and the catheter to a delivery diameter D 1 . This crimping can be done manually or with the aid of tooling specially designed for the purpose either by the physician or the manufacturer. In the crimped position, stent we closely conforms to the overall profile of balloon 114 , inflatable tube component 116 and the catheter except for the slight slack or looseness due to recoil crimping. Tube component 116 is fluid inflated to the extent necessary to compensate for this slack or looseness due to recoil crimping. The pressure of force required to inflate tube component 116 to this extent is also referred to as securement pressure, i.e., the force or pressure needed to secure stent 112 in this position. It is to be noted that, since tube component 116 is designed and constructed to be capable of filly expanding to no more than the size necessary to compensate for recoil crimping, there is no possibility of stent 112 expanding or beginning to open to a larger diameter. Thus, there is no hazard of stent 112 moving out of its position on the catheter during delivery or of becoming separated from the catheter within a body vessel. The catheter distal end is delivered by standard techniques to the deployment site within the body vessel of interest. At this point, stent 112 is positioned as required by the physician and balloon 114 is fluid inflated by standard technique to expand stent 121 to its deployment diameter D 2 . During this expansion, stent 112 is expanded to fill the body vessel. Following deployment of stent 112 , balloon 114 and optionally, tube component 116 are deflated and the assembly 110 is retracted proximally and withdrawn from the body. If required by the procedure, the site of entry to the body is appropriately closed.
[0054] The method of using the stent delivery and deployment assembly 130 of this invention, as shown in FIG. 13, is similarly described. The assembly 130 is constructed as described above. Stent 142 is compressed or crimped to closely conform to the overall profile of balloon 134 , inflatable pouches 136 , 138 , 140 and the catheter except for the slight slack or looseness due to recoil crimping. Pouches 136 , 138 , 140 are each fluid inflated to the profile shown in FIG. 13 through separate fluid inflation conduits (not shown) to securement pressure to compensate for this slack or looseness and to secure stent 142 in this position. The overall configuration of pouches 136 , 138 140 further serves to position stent 142 against axial dislocation during delivery. The catheter is delivered by standard techniques to the deployment site within the body vessel of interest. At this point, stent 142 is positioned as required by the physician and balloon 134 is fluid inflated by standard technique to expand and deploy stent 142 . Following deployment of stent 142 , balloon 134 and, optionally, pouches 136 , 138 140 are deflated and the assembly 130 is retracted proximally and withdrawn form the body. If required by the procedure, the site of entry to the body is appropriately closed.
[0055] The inflation tube component provided by this invention also maximizes stent securement force by optimizing the frictional force between the inflating tube component, the balloon wall and the internal diameter of the stent in its reduced crimped delivery diameter. The inflation tube component is more flexible than a solid sheath under the expandable balloon, and thus the entire assembly has greater flexibility. This invention has particular advantages for assemblies in which the stent is provided for use as pre-crimped to the balloon and underlying catheter, by increasing the shelf life of the pre-crimped assembly. The features and principles described for this invention are suitable for use with fixed wire, over-the-wire and single operator exchange assemblies.
[0056] It should be understood that the various elements and materials of all embodiments could be utilized in each of the other embodiments if desired.
[0057] The above examples and disclosures are intended to be illustrative and not exhaustive. These examples and descriptions will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the attached claims. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims attached hereto.
|
An assembly for delivery and deployment of an inflation expandable stent within a vessel is comprised of a catheter, an inflation expandable stent, an expandable balloon, and a securement means such as a corrugated tube component or an expandable tube component. The tube component is mounted on the inner shaft beneath the balloon and provides increased securement to the stent in a reduced delivery diameter to maintain the stent on the catheter during delivery to the deployment site. The tube component is adhered to the inner shaft and has a plurality of ribs or is fluid expandable to no more than the delivery diameter. and may be comprised of more than one separately inflatable pouch expandable to provide the stent with a substrate seat with increased friction and to decrease the slack in stent recoil crimping. The assembly is used in a method for delivering and deploying a stent, and also adds safety when loading/crimping the stent onto a balloon.
| 0
|
RELATED APPLICATIONS
This application is a Continuation of U.S. application Ser. No. 09/446,246 filed on Dec. 15, 1999 now U.S. Pat. No. 6,659,158, which was the National Stage of International Application No. PCT/EP98/03773, filed on Jun. 19, 1998.
FIELD OF THE INVENTION
The invention relates to a quick-action rolling shutter door and to modules thereof.
BACKGROUND OF THE INVENTION
Quick-action rolling shutter doors are used for closing openings in the walls of warehouses or factory buildings. Here, it is very important that the quick-action rolling shutter door can be opened and closed fast, only leaving the opening in the wall open for the actual passage of a person or a vehicle there-through. This will, on the one hand, restrict any loss of energy from heated or cooled rooms, and, on the other hand, protect the environment by keeping escaping noise, odors and dust emissions to a minimum.
From practical applications, two types of quick-action rolling shutter door are known. A first type of quick-action rolling shutter door, usually referred to as sectional door, uses rigid door elements which are guided on their sides and, when opened, assume a position parallel to a building wall or ceiling. Said door elements generally include a frame with plural filling inserts of a sandwich construction, similar to the kind used in window or door systems. The K-value of said doors which is between 1.0 to 1.4 can in itself be regarded as good from an energy saving point of view. What is disadvantageous about these doors, however, are their low opening and closing speeds and the high technical effort, amongst other things due to the problems involved in foam-filling the filling inserts with construction material. This construction is not only very problematic when it comes to recycling, but does not afford sufficient protection from burglary, either, since the filling inserts do not offer any resistance.
Another type of quick-action rolling shutter door which is known from practice as the so called hanging or curtain door, uses a thin-walled plastic tarpaulin which is guided on the sides and can be wound up onto a roller. The high opening and closing speeds of this type of quick-action rolling shutter door are obtained at the expense of insufficient thermal insulation, with K-values ranging from 4.0 to 5.75, as well as insufficient safety from burglary.
Both types of quick-action rolling shutter door have disadvantages in relation to heat insulation. The disadvantage of sectional doors in this respect is the formation of cold bridges in the region of the joints interconnecting the individual door elements. The insufficient heat insulation of hanging doors is due to the insufficient insulation properties of the material of the hanging.
Another disadvantage of the prior art quick-action rolling shutter doors is the labor-intensive repair of collision damage. With both types of quick-action rolling shutter door, due to the prior art guiding devices used in them, maintenance work is only possible in the raised, opened state. What makes this shortcoming especially serious is the fact that collisions of vehicles and quick-action rolling shutter door hangings or door elements occur very frequently with quick-action rolling shutter doors. Another disadvantage of the prior art types of quick-action rolling shutter door resides in their insufficient safety from burglary, as already mentioned.
SUMMARY OF THE INVENTION
It is the object of the invention to provide an improved quick-action rolling shutter door with corresponding modules for improving prior art quick-action rolling shutter doors.
This object is solved according to the invention by the features of the claims.
In accordance with claim 1 , the flexible hanging of the quick-action rolling shutter door, which is wound up onto a roller and guided on at least one side by a guiding device, should have at least one thick-walled insulating layer consisting of foamed plastic material. The fact that foamed plastic material is used, which has pores and chambers with small air cushions preventing any heat exchange through the quick-action rolling shutter door hanging, results in good heat and cold insulation. To achieve such insulation does not require a major constructional effort since the quick-action rolling shutter door hanging is flexible and can thus be readily wound up onto a roller. This allows high-speed opening and closing actions. Consequently, there will be no hinges, either, which would require special insulation measures.
The hanging of the quick-action rolling shutter door which constitutes a module for a quick-action rolling shutter door and for which protection is also sought separately, independently of claim 1 , preferably exhibits some reinforcement onto which the thick-walled insulation layer has been laminated. Said reinforcement, which may comprise a fabric or web of steel wires, steel strands, glass or carbon fibres, or cotton, serves as a barrier preventing any cutting through said quick-action rolling shutter door hanging, thus preventing burglary. A particular good cost-effectiveness ratio is obtained when a steel fabric is used for reinforcement.
For facilitating the winding up of the quick-action rolling shutter door hanging, one of its external sides preferably has expansion slots. In the case of a quick-action rolling shutter door hanging with first and second insulation layers, such layers are preferably glued or welded together along contact lines extending transversely to the direction of travel of said quick-action rolling shutter door. Particularly suitable for gluing together insulating layers of polyethylene foam is cyancacrylate.
Another quick-action rolling shutter door module for which independent protection is sought, is the anti-push-up device as claimed in claim 15 . This anti-push-up device, which is provided especially for quick-action rolling shutter doors, is characterized by at least one detent latch which will latch in the guiding device whenever the distance between adjacent track rollers or sliding elements decreases during opening of the quick-action rolling shutter door. The distance between adjacent track rollers or sliding elements will always decrease when the bottom edge of a quick-action rolling shutter door hanging, or of door elements which are slidable relative to each other, is to be lifted. The fact that said at least one detent latch latches in said guiding device will prevent any further lifting of the quick-action rolling shutter door hanging or the door elements in such a case, thus preventing any burglary attempts in this manner. A bracing spring which will force two detent latches apart whenever the quick-action rolling shutter door hanging or the door elements is/are lifted, facilitates the latching process.
Yet another quick-action rolling shutter door module which is very advantageous when used together with a quick-action rolling shutter door hanging of the present invention, is a guiding device for quick-action rolling shutter doors, comprising a guide rail which is essentially U-shaped in cross-section and has a guide space for accommodating track rollers or sliding elements, wherein said guide rail is composed of plural parts. The two legs of the guide rail, which extend essentially in parallel in operation, can be shifted relative to each other, making the guide space freely accessible in its opened state. The fact that the guide space is freely accessible in its opened state allows the maintenance of a quick-action rolling shutter door equipped with such a guiding device in its closed state, which in particular makes an exchange or the cleaning of track rollers or sliding elements of a quick-action rolling shutter door possible. As the quick-action rolling shutter door can be kept closed during maintenance, any energy losses and emissions will be minimal. Moreover, this will facilitate maintenance work since the quick-action rolling shutter hanging and its guiding device are easily accessible.
Another way of minimizing the maintenance and repair work involved in operating a quick-action rolling shutter door is to provide a crash protection device. Such crash protection device for quick-action rolling shutter doors, for which independent protection is also sought, will ensure that the full operativeness of the quick-action rolling shutter door is restored in as short a time as possible after a vehicle has crashed into the hanging or the door elements of the quick-action rolling shutter door. While with quick-action rolling shutter doors of the prior art, parts of the guiding device will become destroyed in a collision, the crash protection device of the invention overcomes this problem in that, in case of a collision with a vehicle, it allows for the releasing of a coupling, thus avoiding the destruction of an element of the guiding device. Preferably, said coupling is designed such that coupling elements which were decoupled or disengaged during the raising of the hanging or door elements of the quick-action rolling shutter door will automatically be coupled or engaged again at funnel-like guide means.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantageous embodiments and further developments of the invention will become apparent from the subclaims as well as the description which follows in which reference is made to the drawings, of which:
FIG. 1 is a view of a first embodiment of a quick-action rolling shutter door according to the invention, with the roller cover removed;
FIG. 2 is a simplified perspective view of the top part of the quick-action rolling shutter door of FIG. 1 ;
FIG. 3 is a cut-off perspective view of a hanging for a quick-action rolling shutter door of FIGS. 1 and 2 ;
FIG. 4 is an enlarged perspective view of a first section of the quick-action rolling shutter door hanging of FIG. 3 ;
FIG. 5 is an enlarged perspective view of a second section of the quick-action rolling shutter door hanging of FIG. 3 ;
FIG. 6 is a guiding device according to the invention for a quick-action rolling shutter door of FIGS. 1 and 2 ;
FIG. 7 is one view of an anti-push-up device according to the invention for a quick-action rolling shutter door of FIGS. 1 and 2 ;
FIG. 8 is a simplified view of a pair of detent latches of the anti-push-up device of FIG. 6 ;
FIG. 8 a is a pair of detent latches for a second embodiment of an anti-push-up device, including a torsion spring for forcing said detent latches apart;
FIG. 9 is one view of a section of a crash protection device according to the invention;
FIG. 10 is a sectional view, taken along lines IX—IX of FIG. 8 , of said crash protection device of FIG. 8 with a quick-action rolling shutter door hanging;
FIG. 11 is a simplified perspective view of a coupling of the crash protection device of FIGS. 8 and 9 ;
FIG. 11 a is a simplified view of another embodiment of a coupling for a crash protection device of FIGS. 8 and 9 ;
FIG. 11 b is a view of the coupling of FIG. 11 a as indicated by arrow XI therein, in the coupled state;
FIG. 12 is a simplified view of a second embodiment of the quick-action rolling shutter door of the invention;
FIG. 13 is a view of a second embodiment of the quick-action rolling shutter door hanging of the invention;
FIG. 14 is a view of the reinforcement of the quick-action rolling shutter door hanging of FIG. 13 ;
FIG. 15 is a sectional view of a variant of the quick-action rolling shutter door hanging of FIG. 13 including expansion slots;
FIG. 16 is a cut-open view of a portion of the quick-action rolling shutter door hanging of the invention including a transverse girder that may be partitioned longitudinally in operation according to yet another embodiment and a longitudinal strip of a reinforcement;
FIG. 17 is a cut-open view of a portion of the quick-action rolling shutter door hanging of the invention including a transverse girder according to yet another embodiment and a longitudinal strap of a reinforcement.
DETAILED DESCRIPTION OF THE INVENTION
The first embodiment of a quick-action rolling shutter door 10 according to the invention, shown in FIGS. 1 to 6 , consists of plural quick-action rolling shutter door modules. A first quick-action rolling shutter door module is the quick-action rolling shutter door hanging 12 which is guided on the side and at the top by a guiding device 14 . Said guiding device 14 includes a roller 16 which can be driven to rotate in either direction by a motor 18 . Said motor 18 is controlled by controlling means 20 which will also process signals from contact rails and light barriers supplied via signal lines 22 .
FIG. 2 shows the top part 24 of the guiding device 14 . It can clearly be seen in this Figure that the guiding device 14 essentially comprises two lateral guide rails 26 , 28 as well as a head beam 30 maintaining the distance between said two guide rails. Extending in parallel to said head beam 30 is a roller 16 supported in roller support means 32 .
Crucial for the quick-action rolling shutter door 10 is the quick-action rolling shutter door hanging 12 , a first embodiment of which is shown in detail in FIGS. 3 to 5 and further embodiments of which are shown in FIGS. 13 to 17 . Like parts are marked with like reference numerals, but increased by 1,000 or 2,000. The quick-action rolling shutter door hanging 12 of the first embodiment illustrated in FIGS. 3 to 5 has a continuous reinforcement 34 of a steel wire fabric, one side of which is laminated with a first insulating layer 36 of a thickness of 25 mm and the other side of which is laminated with a second insulating bayer 38 , likewise 25 mm thick. For use as a burglary-proof door on the outside, a steel fabric is laminated into the foamed material. The steel fabric may be of a thickness of between 0.3 mm to 1 mm. The first and second insulating layers comprise a closed-pore polyurethane foam of a density of 30 kg/m 3 . The first insulating layer is intended to be the external layer and has a smooth fair-faced side 40 which is of the same color as the actual building. The likewise smooth fair-faced side 42 of the insulating layer 38 intended to face inside, by contrast, which may also be customized, is in a glaring color.
The thick first insulating layer, however, may also be structured on the outside, which creates the visual impression of a sectional door.
The quick-action rolling shutter door hanging 1012 partially shown in sectional view in FIG. 13 , whose reinforcement is not shown therein to keep the drawing simple, has two insulating layers 1036 , 1038 , which—as opposed to the quick-action rolling shutter door hanging 12 of the first embodiment—are not glued onto each other over their entire surfaces, but merely along contact or glue lines 1002 . Said insulating layers 1036 , 1038 are made of a cross-linked foamed polyethylene material marked by HT-Troplast AG under the trade name TROCELLEN R under the specification 3015 SWB F4 UV. This cross-linked foamed polyethylene material has a raw density of 33±3 kg/m 3 , a longitudinal tensile strength of 0.42 N/mm 2 , a transverse tensile strength of 0.29 N/mm 2 , a ductile yield, in the transverse and longitudinal directions, of approximately 200 percent, a temperature application range in the bending test of up to minus 40° C., a dimensional stability up to plus 95° C., a thermal conductivity at 30° C. of 0.038 w/m K, and a water vapour diffusion current density of <3 g/m 2 d with a thickness of 10 mm.
Further materials suitable for insulating layers are available from ALVEC under the trade name ALVEOLIT R . The properties of these materials may be noted from the table below:
ISO
Properties
Standard
Unit
TA
TA FR
Raw Density
845
kg/m 3
25
25
Tensile Strength
1926
longitudinal
kPa
280
235
transverse
kPa
180
155
Ductile Yield
1926
longitudinal
%
125
115
transverse
%
105
95
Upsetting hardness
844
Upsetting 10%
kPa
12
13
Upsetting 25%
kPa
32
32
Upsetting 50%
kPa
92
92
Pressure Deformation
1856-C
Remainder, 22 h
strain, 23° C.
Upsetting 25%
0.5 h after strain relieve
%
22
21
24 h after strain relieve
%
13
13
Thermal Conductivity
2581
at 10° C.
W/mK
0.034
0.034
at 40° C.
W/mK
0.038
0.039
Operating Temperature
in-house
° C.
−80/+100
−80/+100
Range
Water Absorption (7 days)
in-house
% v/v
<1
<1
Water Vapour Permeability
1663
g/m 2 × 24 h
3.8 (2 mm)
(Thickness)
μ value (23° C., 0-85% r.F)
1663
5500
Shore Hardness 0/00
in-house
17/33
15/34
Unit
Properties
ISO
Standard
TA FRS
TA FRB
TA FMl
Raw Density
845
kg/m 3
25
25
25
Tensile Strength
1926
longitudinal
kPa
225
235
225
transverse
kPa
140
150
145
Ductile Yield
1926
longitudinal
%
100
110
100
transverse
%
80
100
90
Upsetting Hardness
844
Upsetting 10%
kPa
12
12
12
Upsetting 25%
kPa
31
32
32
Upsetting 50%
kPa
80
95
93
Pressure Deformation
1856-C
Remainder, 22 h
strain, 23° C.,
Upsetting 25%
0.5 h after strain
%
22
21
21
relieve
24 h after strain
%
13
13
14
relieve
Thermal Conductivity
2581
at 10° C.
W/mK
0.034
0.033
0.033
at 40° C.
W/mK
0.039
0/037
0.037
Operating
in-house
° C.
−80/+100
−80/100
−80/+100
Temperature Range
Water Absorption (17
in-house
% v/v
<1
<1
<1
days)
Water Vapour
1663
g/m 2 × 24 h
1.8 (5.5 mm)
Permeability
(Thickness)
μ value (23° C., 0-
1663
4100
85% r.F)
Shore Hardness 0/00
in-house
16/29
18/29
17/27
FIG. 15 shows a variant of the quick-action rolling shutter door hanging 1012 of FIG. 13 . This variant of a quick-action rolling shutter door hanging 2012 has expansion slots 2004 on its external side which expand to form notches 2006 during the winding up of the quick-action rolling shutter door hanging 2012 , thus contributing to a strain reduction within the material of the quick-action rolling shutter door hanging 2012 and facilitating the winding up onto rollers.
FIG. 14 shows a reinforcement 1034 for the quick-action rolling shutter door hanging which comprises first and second transverse girders 1300 , 1302 as well as longitudinal strips 1304 . The first transverse girders 1300 are simple aluminum profiles of rectangular cross-section which extend transversely to the direction of travel of the quick-action rolling shutter door hanging and are connected to longitudinal strips at regular intervals by means of through bolts. The longitudinal strips 1304 are flexible metal strips which may easily be wound up, but present a strong resistance towards being cut by knives or other cutting tools. FIG. 17 shows a first transverse girder 1300 and longitudinal strip 1304 together with first and second insulating layers 1036 , 1038 , respectively.
FIG. 16 shows a portion of a quick-action rolling shutter door hanging 1012 with a second transverse girder 1302 which consists of two parts. Said second transverse girder comprises a first transverse girder part 1306 and a second transverse girder part 1308 , which two parts are slid into each other such that they can be slidingly separated along a parting line 1310 . Said first and second transverse girder parts 1306 , 1308 each have two insertion channels 1312 , 1314 accommodating the insulation layers 1036 , 1038 . For interconnection or, if necessary, for connection to first transverse girders 1300 , longitudinal strips 1304 are again provided. Said longitudinal strips 1304 are bent U-shaped around holding means 1316 so as to ensure a safe connection of said longitudinal strips 1304 to said transverse girder parts 1306 , 1308 via a screwed connection of said longitudinal holding means 1316 . For use of the quick-action rolling shutter door hanging 1012 in an environment where heat or cold insulation is important, the second transverse girders 1302 should be designed such that they will not form cold bridges. To this end, the profiles from which the transverse girder parts 1306 , 1308 are made may be provided with insulating ribs. As an alternative, second transverse girders 1302 need not be provided altogether since, if first transverse girders 1300 are used exclusively, as shown in FIG. 17 , there will not be any cold bridges.
As an alternative to the insulating layer material described, other materials may also be used in the insulating layers, comprising a flexible open- or closed-cell foamed material of a chemically or physically cross-linked type. A closed skin is advantageous. Materials of foamed polyolef ins of a temperature stability up to at least −35° C., preferably −40° C., and a K-value of <2.5 are particularly suited.
Foamed materials which are especially well suited are:
PE—Polyethylene:
Reusable—UV proof—available in any color, behaviour in fire: DIN 4102 B1, B2 class—temperature application range −40° C. up to 105° C. K-value of between 1 and 1.4—raw density of between 30 and 250 kg/m 2 . Foam thickness of between 10 mm and 40 mm for the door insert.
PU—Polyurethane:
Recyclable, UV proof, extremely sound absorbing, temperature stability 40° C. up to, for a short time, 170° C. K-value 1 to 1.4, raw density between 30 and 250 kg/m 2 . Behaviour in fire: DIN 4102 B1, B2 class. Foam thickness of between 10 mm and 40 mm for the door insert.
EPDM—Synthetic Rubber:
Recyclable and suitable for disposal in household rubbish, UV proof, fire behaviour DIN 4102 B1, B2 class. Temperature stability from −57° C. to 150° C. Foam thickness of between 10 mm and 40 mm for the door insert.
PVC—Polyvinylchloride.
For absorbing the wind forces acting on the quick-action rolling shutter door hanging (FIG. 3 ), antibuckling profiles 44 are provided. These profiles 44 extend on either side of the reinforcement 34 transversely to the direction of travel of the door, bridging the distance between the guide rails 26 , 28 of the guiding device 14 , and may also serve as the transverse girders of a reinforcement. Said antibuckling profiles 44 extend essentially Z-shaped and have one leg engaging said reinforcement. Their respective other leg engages the external side of the respective insulating layer 36 , 38 , thus subdividing said insulating layer 36 , 38 into individual portions. Since said insulating layers 36 , 38 are flexible, as is notable from FIG. 3 , and said antibuckling profiles 44 are of low height, the quick-action rolling shutter door hanging 12 of FIGS. 3 to 5 may be wound up onto roller 16 .
In order not only to prevent any strong bending or deflection of the quick-action rolling shutter door hanging 12 , but to ensure a reliable support of the quick-action rolling shutter door hanging 12 at the same time, track roller means 46 are provided at the ends of said antibuckling profiles 44 which are opposite each other, with said reinforcement 34 in-between. Said track roller means 46 —also illustrated in FIG. 6 —includes an axle body 48 on which two roller bodies 52 , spaced from each other by means of a sleeve 50 , are rotatably mounted. One of said roller bodies 52 contacts support screw means 54 provided at one end thereof. The second roller body is supported by a grab body 58 , screwed onto said axle body 48 and including a slot 56 , so as to loosely contact said sleeve so. In this state, said grab body 58 also encompasses ( FIG. 5 ) a leg each of two opposing antibuckling profiles 44 to which it is at the same time glued, soldered or welded, depending on the material of said antibuckling profiles 44 .
FIG. 6 illustrates how said roller bodies 52 , which are supported on their respective axle body 48 and may also be referred to as tandem rollers, are guided in their respective guide rail 26 .
The guide rail 26 shown in FIG. 6 includes a support body 60 made of a rectangular square profile. Mounted on said support body 60 by means of a hinge 62 is a swivelling part 64 made of an equal angle profile. The edge length of said swiveling part 64 is somewhat longer than that of the support body, enabling said swivelling part 64 to encompass said support body 60 , with a reference edge 66 of said swivelling part and a reference surface 68 of said support body 60 being essentially on one plane at the same time so as to define an oblong aperture 70 therebetween for the quick-action rolling shutter door hanging 12 .
In the state illustrated in FIG. 6 , the free leg 72 of the swivelling part 64 extends essentially in parallel to a longitudinal wall 74 of the support body 60 so that these two elements, i.e., the longitudinal wall 74 of said support body 60 and the free leg 72 of said swivelling part 64 , function almost like parallel legs of a U profile. In order to maintain said support body 60 and said swivelling part 64 in this relative position and thus to prevent this constellation from coming apart in operation, a screwed connection 76 is provided which extends through said swivelling part 64 and engages a threaded bore in said support body 60 .
The guide rail shown in FIG. 6 is intended for assembly within a refrigerating chamber. In order to prevent the roller bodies 52 from freezing up and thus blocking, the guide chamber 78 defined by the longitudinal wall 74 and the free leg 72 is lined with heat insulation elements 80 which have at least one heating coil 82 on their internal side for heating said guide chamber 78 . Brush bodies 84 provided on either longitudinal side of said aperture 70 will prevent any excessive heat loss from said guide chamber 78 .
In order to prevent the rolling shutter door hanging from being pushed up, said quick-action rolling shutter door 10 may be equipped with an anti-push-up device 84 . Such an anti-push-up device 84 , which is shown in FIGS. 7 and 8 , includes two detent latches 86 , 88 which are rotatably mounted on the axle body 48 of lower track roller means 46 . In this construction, the centre of gravity of said two detent latches 86 , 88 is above the axis of rotation of said axle body 48 , in an off-centre position. As a consequence, under the influence of gravity, both detent latches 86 , 88 would therefore rotate about the axis of rotation of said axle body 48 in opposite directions, if such movement were not prevented for the moment by a retaining belt 90 . If the rolling shutter door hanging 12 were pushed up, however, the retaining belt 90 , which is suspended from the axle body 48 above the axle body 48 bearing the detent latches 86 , 88 , would become relieved, resulting in said two detent latches 86 , 88 rotating until they are stopped by the walls of the guide chamber 78 of the guide rail 26 .
FIG. 8 a shows a variant of an anti-push-up device in which the detent latches 86 ′, 88 ′ are pre-biased by a twisting spring 89 .
FIGS. 9 to 11 illustrate a crash protection device 92 preventing the destruction of track roller means in the case of a collision of a vehicle with the quick-action rolling shutter door hanging 12 . The crash protection device 92 , which may be provided as an alternative to the anti-push-up device 84 , includes track roller means 94 guiding a coupling 96 . Said coupling 96 includes a clamp roller 98 which is accommodated in a support channel 100 of a clamp body 102 . Said clamp body 102 is screwed to a floor rail 104 forming the bottom end of the quick-action rolling shutter door hanging 12 . In this construction, the support channel 100 of the clamp body 102 is oriented so as to extend transversely to the extension of the quick-action rolling shutter door hanging 102 . A minimum holding force between clamp roller 98 and clamp body 102 is obtained in that clamp roller 98 has a rubber-elastic running surface and in that the support channel 100 within said clamp body 102 is concavely shaped both at the top and at the bottom.
So as to enable the clamp roller 98 to become decoupled from the clamp body 102 in the case of a collision, the quick-action rolling shutter door hanging 12 , in the region of the crash protection device 92 , is cut such that it will not project into the guide rail 26 . In order to safeguard a tight closing nonetheless, a cover 106 is provided where the crash protection device 92 is, which cover 106 is of a design corresponding to the laminated construction of the quick-action rolling shutter door hanging 12 and connects the bottom-most track roller device 94 with the track roller device 108 above it. Besides this cover 106 , coupling belts 110 are provided which keep track roller device 94 and track roller device 108 at a fixed distance from each other.
In order to accomplish a good sealing between said cover 106 and said quick-action rolling shutter door hanging 12 , the opposing edges 112 and 114 of said cover and said quick-action rolling shutter door hanging 12 , respectively, are curved complementary towards each other, leaving merely a small sealing gap 116 between them. Since both the quick-action rolling shutter door hanging 12 and the cover 106 are made of an elastic material, the quick-action rolling shutter door hanging 12 and the cover 106 will overlap. During decoupling of the crash protection device 92 , some material of the quick-action rolling shutter door hanging 12 and of the cover 106 will be compressed, leaving the lower portion of the quick-action rolling shutter door hanging 12 free.
FIGS. 11 a and 11 b illustrate a clamp body 102 ′ for a second embodiment of a coupling for a crash protection device. Said clamp body 102 ′ is in two parts, i.e. it comprises upper and lower clamp body halves 1400 , 1402 which are both inserted in a recession of a profile 1404 extending transversely to the direction of travel of the door. The (common) end 1406 of said upper and lower clamp body halves 1400 , 1402 which faces a clamp roller 98 ′ is shaped like the clamp body 102 of FIGS. 9 to 11 , with the only exception that no wheel-like projection is being encompassed here.
The upper and lower clamp body halves 1400 , 1402 support each other at a contact surface 1408 and each have bevel or chamfered portions on the side opposing the clamp roller so as to leave a free portion 1410 between them, allowing a pincer-like movement of the two clamp body halves 1400 , 1402 towards each other, either to release or to reaccommodate the clamp roller 98 ′. For pre-biasing the two clamp body halves 1400 , 1402 in their holding position, a helical spring 1412 is provided at the end of the clamp body opposing the clamp roller 98 ′, with a pressure load acting on said spring 1412 along its longitudinal axis, said spring 1412 being guided in chambers 1414 , 1416 of the upper or lower clamp body halves 1400 , 1402 , respectively.
The quick-action rolling shutter door 10 shown in FIGS. 1 to 6 can be readily assembled within a very short time according to a scheme known from the furniture industry including assembly instructions in the form of illustrations (FIG. 2 ). The guide rails 26 , 28 and the top 24 , which are manufactured according to specifications of the clear dimensions, are prefabricated in production in such a way that the user will not have to perform major measurements owing to the specified screwed connections and mountings, and that these parts allow easy assembly according to the unitized construction principle. First of all, the guide rails 26 , 28 are laid out on the floor, screwed to transverse girders and mounted in the wall opening. The screwed connections of the roller support means to the shaft, hanging, motor and the transverse girders were already provided by the manufacturer. Using a forklift truck, the user will lift the prefabricated roller support means and insert it in the mountings intended for this purpose. Subsequently, the top part is secured (in position) by means of screws.
It should further be noted that, in view of the bending behaviour of the foamed material and the steel fabric contained therein, the shaft diameter should be 200 mm at least.
A second embodiment of a quick-action rolling shutter door 210 according to the invention is illustrated in FIG. 12 . This quick-action rolling shutter door 210 has a quick-action rolling shutter door hanging 212 which is vertically divided at the centre. The upper end of said hanging 212 extends in a guide rail 226 of a guiding device 214 , and said hanging 212 may be laterally wound up onto a first roller 216 and a second roller 217 . The quick-action rolling shutter door hanging 212 has two mutually complementary magnet rails at its centre which keep the quick-action rolling shutter door hanging 212 together at its centre in its closed state. For increasing safety around the quick-action rolling shutter door 210 , two windows 213 are provided in said quick-action rolling shutter door hanging 212 , which windows 213 are of a transparent plastic material and are welded onto the material of the quick-action rolling shutter door hanging 212 . A quick-action rolling shutter door hanging of this design is also advantageous in a quick-action rolling shutter door of the first embodiment. The quick-action rolling shutter door hanging 212 which is identical in construction to the hanging 12 of the quick-action rolling shutter door 10 of the first embodiment, may readily be provided with windows 213 since its closed-pore insulating layers do not require any sealing or bordering.
|
A quick-action rolling shutter door and modules thereof used for closing openings in the walls of warehouses or factory buildings in order to restrict the loss of energy from heated or cooled rooms, and to protect the environment by keeping escaping noise, odors and dust emissions to a minimum. A flexible quick-action rolling shutter door hanging ( 12 ) can be wound up onto a roller, is guided on at least one side by a guiding device, and has at least one thick-walled insulating layer ( 36, 38 ) consisting of plastic foam material.
| 4
|
BACKGROUND OF THE INVENTION
The present invention relates to the remote connection of subsea flowlines and, in particular, to method and apparatus for connecting subsea pipelines to a submerged structure without the use of divers. More particularly, the invention concerns attaching subsea pipelines to subsea manifolds employing a connecting tool which is capable of aligning, clamping, testing and maintaining the connections between the pipelines and the manifold.
SUMMARY OF THE INVENTION
The present invention provides improved method and apparatus for connecting a spool piece hub, connected to the manifold of a subsea structure or template, to a pipeline hub. In the method a remotely operated pipeline connecting tool is lowered from a surface vessel to the template and properly positioned over the pipeline and manifold hubs. The connector tool is latched to the spool piece and the spool piece hub and pipeline hub are drawn together by hydraulic cylinders attached to sliding frames on the connecting tool. The hubs are then clamped together and pressure tested.
To retrieve a spool piece for replacement the connecting tool is lowered and latched onto the spool piece which is disconnected by unclamping the spool piece hubs from the manifold and pipeline hubs. The sliding frames on the connecting tool spread the manifold and pipeline hubs and the connecting tool is locked to the spool piece which is lifted from between the hubs and retrieved. All connecting tool operations except the alignments are surface controlled, hydraulic power fluid being supplied from a surface vessel.
Prior to lowering the connecting tool a section of the pipeline containing the pipeline hub and a trunnion assembly attached thereto is lowered vertically to adjacent the spool piece hub. As the pipeline hub and trunnion assembly are lowered additional sections of pipe are connected to the initial pipeline section attached to the trunnion assembly. Lowering continues until the trunnion assembly latches to the template. Additional sections of pipe are laid out and during the laying operations the pipeline pivots 90° to the horizontal at the trunnion assembly which places the pipeline hub in final position for connection to the spool piece hub.
The apparatus for carrying out the method of the invention includes a spool piece having one spool piece hub adjacent said pipeline hub for connection thereto and the other hub thereof connected to a manifold hub which connects to a template; clamp means arranged on the spool piece hub for clamping the spool piece hub and pipeline hub together; and a remotely operated connecting tool having guidance frame means engageable with the manifold hub, landing frame means engageable with the pipeline hub, means connecting the guidance frame means and the landing frame means for moving the spool piece hub into connection with the pipeline hub; means for engaging the clamp means for operating the clamp means to clamp the spool piece hub and pipeline hub together and means for releasably locking the connector tool to the spool piece. In addition, conduit means are provided on the clamp means for supplying fluid to the connected hubs to test the connection and means are provided on the connecting tool for connecting the conduit means to a source of fluid. The spool piece may include a hydraulically operable valve, the operation thereof being controlled from the template through connections in the manifold and spool piece hubs.
Further, the apparatus includes two guide posts connected to guidelines; a pipeline section having a pipeline hub; a trunnion assembly attached to the pipeline section and containing guide funnels and a latch for latching onto the template.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 are schematic views of a pipeline hub being positioned on a subsea template in alignment with a spool piece hub in accordance with the method of the invention;
FIG. 3 is a schematic view of a remote pipeline connecting tool positioned on the pipeline and manifold hub assemblies for connecting the spool piece hub to the pipeline hub;
FIG. 4 is a schematic view of the spool piece hub clamped to the pipeline hub;
FIG. 5 is a schematic view illustrating recovery of the connecting tool;
FIG. 6 is a side view which illustrates the apparatus for clamping the spool piece hub to the pipeline and manifold hubs;
FIG. 7 is a view taken along lines 7--7 of FIG. 6;
FIG. 8 is a view illustrating details of the connecting tool;
FIG. 9 is a view taken along lines 9--9 of FIG. 8;
FIG. 10 is a view taken along lines 10--10 of FIG. 8;
FIG. 11 is a fragmentary view illustrating one of the wobble plate assemblies positioned adjacent the spool piece hub;
FIG. 12 is a top view of the wobble plate assembly shown in FIG. 11;
FIG. 13 is a view taken along lines 13--13 of FIG. 12;
FIG. 14 is a view taken along lines 14--14 of FIG. 11; and
FIGS. 15 and 16 are fragmentary views illustrating operation of the latch fingers.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 there is shown a subsea template 10 to which is latched a trunnion assembly 11 by latches 13 having latch releasing arms 13A and to which is pivotally attached by pins 11A a pipeline 14 with a connection hub 15. Trunnion assembly 11 also includes a base member 12, guide funnels 12A and other suitable securing means as, for example, tapered pins extending from base member 12 into holes in template 10, not shown, to fix trunnion assembly 11 on template 10. An isolation valve 16 is located on pipeline 14 adjacent trunnion assembly 11 on which pipeline 14 and hub 15 pivot relative to base member 12. Pipeline 14, hub 15 and trunnion assembly 11 are lowered into position on template 10 by two guide posts 17 positioned on template 10 and guide cables 18 connected to the guide posts. Base member 12 is latched to template 10 by latch 13, as shown. A valve spool piece 19 contains a valve 20 and a hub 21 to which hub 15 is to be connected and a hub 22 which is connected to a hub 23 of a manifold hub assembly 24 connected to manifold piping 24. Valve 20 is a balanced stem fail-safe valve such as described and claimed in U.S. Pat. No. 3,933,338 by D. P. Herd et al. Hub assembly 24 is supported by and shear pinned to a post 27 supporting cone end support 26. Hubs 22 and 23 are clamped together by a clamp assembly 50 and hub 21 is provided with a clamp assembly 51 which is used to clamp it to hub 15. Each clamp assembly is the type clamp connector described and claimed in U.S. Pat. No. 3,843,168 by C. D. Morrill et al. In FIG. 2 pipeline hub assembly 11 is shown pivoted into horizontal and properly aligned with valve spool 19 for connection of hubs 15 and 21.
Referring to FIG. 3 a remote pipeline connecting tool 30 is lowered on drill pipe 31 from the water's surface guided by guide posts 17 and cables 18 and guide sleeves 17A on the connecting tool onto trunnion assembly 11 and manifold hub assembly 24. Connecting tool 30 includes a support frame 32 which provides structural support for the other components of the connecting tool. A valve operator 33 is supported on frame 32. A wobble plate assembly 34 includes vertical plate assemblies 35 and 36 slidably mounted on guide rods 37 and 38 which are secured to frame 32. A pair of piston-cylinder assemblies 39 connect plate 35 of wobble plate assembly 34 and a guidance frame 40. As shown, guidance frame 40 is positioned adjacent hub 23 of the manifold hub assembly 24. A landing frame 41, shown in landed position on trunnion assembly 11, is located adjacent hub 15. A pair of piston-cylinder assemblies 42 connect landing frame 41 and guidance frame 40. Guidance frame 40 is also slidably mounted on guide rods 37 and 38 while landing frame 41 is slidably mounted on guide rods 37. A pair of piston-cylinder assemblies 43 connect landing frame 41 and support frame 32 as shown. Connecting tool 30 in FIG. 3 is in position for moving hub 21 to hub 15.
In FIG. 4 hubs 15 and 21 are shown made up and clamped together by clamp assembly 51 and valve actuator 33 is in position to open or close isolation valve 16. Manifold piping 25 contains a loop, not shown, that acts as a spring to allow manifold hub movement without overstressing the piping.
In FIG. 5 connecting tool 30 is shown being retrieved to the surface following successful testing of the made up connection. FIG. 5 also illustrates lowering of connecting tool 30 into position on trunnion assembly 11 and the manifold hub assembly 24 for removal of spool piece 19.
Referring now to FIGS. 6 and 7 in which the details of spool piece 19 and clamp assemblies 50 and 51 on hubs 21 and 22 are illustrated. Clamp assemblies 50 and 51 each include a vertical plate 52 bolted to each hub 21 and 22 by bolts 53. A pair of horizontal plates 54 on each clamp assembly support a pair of guide sleeves 55 and clamp operating rods 56 which are provided with hex shaped wrench heads 57. Also supported on one of the horizontal plates 54 is the male half of test hydraulic connector 58 which is connected by a conduit 59 to a port, not shown, on each hub 21 and 22 between seals 60 and 61 (indicated on the contacting surface face of hub 21). Clamp halves 62 are shown threaded onto rods 56. The clamp assemblies are in closed position on hub 22 and in the open position on hub 21. A semicircular saddle sleeve 66 is fixed to the back of plate 52.
Plate 52 has an opening 63 at its upper end forming lug ears 64 which are shown engaged by latch fingers 65 (see FIG. 7).
Guidance frame 40, as seen in FIGS. 8 through 10, includes guide yoke 40A, the lower tapered, wedgeshaped portion of which aids in moving manifold hub assembly 24 into proper position with respect to spool piece 19. Each plate assembly 35 and 36 includes a plate 73 and a wobble plate 74, the latter being pulled against plate 73 by tie rods 75. Guidance frame 40 is attached to sleeves 70 which slide on guide rods 37 and 38. Plates 73 of wobble plate assembly 34 are attached to sleeves 71 which slide on guide rods 37 and 38. Landing frame 41 is attached to sleeves 72 which slide on upper guide rods 37. A plate 76 is movably mounted on a roller 77 which is attached to each wobble plate 74. Attached to the underside of each plate 76 are downwardly extending guide pins 78. Each plate 76 also has a pair of torque motors 79 attached to it.
In FIG. 11 it is seen that each motor 79 is attached to a wrench 80 which extends below plate 76 and is positioned to engage a hex head 57 of the clamp assemblies. Each wobble plate 74 sits on a semicircular shoulder 81 attached to plate 73 by bolts 82. The center portion 83 of the upper surface of each wobble plate 74 is formed as a curved surface having a center point 84 which is also the center point for the semicircular surface 91 on shoulder 81. A roller 85 is mounted on plate 73 and bears against curved surface 83. A pair of centering springs 86 surround pins 87 which are attached to the upper end of plate 74 and extend through spring retainer boxes 88 which are attached to plate 73 by bolts 89. Each of the two tie rods 75 extend through an enlarged opening 90 in plate 73. The limited movement afforded by the mountings of plates 74 and 76 permits adjustments in aligning guide sleeves 55 with guide pins 78 and hex heads 57 with wrenches 80. When the wobble plates are lowered into position on valve spool 19 surfaces 91A engage saddle sleeves 66. In that position of connecting tool 30 guide pins 78 are aligned in sleeves 55 and wrenches 80 engage wrench heads 57.
Referring to FIGS. 12 through 16, in which details of the latch assemblies are shown, latch pins 65 are mounted in openings 95 on a rod 96 which is mounted for rotation in each wobble plate 74. A piston-cylinder assembly 97 is pivotally connected at one end to wobble plate 74, as at 98, and at the other end to link arm 99 which is also attached to rod 96. When shoulder 81 engages saddle sleeve 66 (see FIG. 11) latch fingers 65 are in position within opening 63 to be extended and engage underneath ears 64. Once so extended, spring fingers 76 lock connecting tool 30 to spool piece 19.
In operation, after guide posts 17 and guidelines 18 are installed at a prepared location on template 10 trunnion assembly 11, with pipeline 14 and hub 15 attached, is lowered with guidelines 18 within the two guide funnels 12A of the trunnion assembly. As trunnion assembly 11 is lowered additional sections of pipe are joined to the original pipeline section. Addition of pipe sections continues until guide funnels 12A slide over guide posts 17. Lowering continues until latches 13 latch trunnion assembly 11 to template 10. As additional sections of pipeline are laid out pipeline section 14 is pivoted 90° from vertical to horizontal which places pipeline hub 15 in final position for connection to spool piece hub 21.
Connecting tool 30 is then lowered with guidelines 18 within guide sleeves 17A to guide posts 17 where initial alignment is achieved. As lowering continues guidance yoke 40A of guidance frame 40 engages manifold hub assembly 24 between hub 23 and cone-shaped support 26. The three points of alignment, the two guide posts and the manifold hub correctly position connecting tool 30 over pipeline hub 15 and spool piece hub 21. Lowering continues and the weight of connecting tool 30 is landed on trunnion assembly 11 by landing frame 41. The hydraulically powered landing frame 41 is retracted by piston-cylinders 43 and the entire connecting tool 30 drops from its landing point into position for pipeline connection. During the last downward movement wobble plate assembly 34 permits final alignment of guide pins 78 and sleeves 55. Latch fingers 65 are activated to lock connecting tool 30 and spool piece 19 together. Spool piece hub 21 and pipeline hub 15 are drawn together by hydraulic cylinder assemblies 42 attached to sliding guidance and landing frames 40 and 41, respectively, of connecting tool 30. Movement of manifold piping 25 toward pipeline hub 15 disconnects the manifold piping 25 from post 27 by shearing the pins connecting them. The female half of connector 58 on hydraulic connecting tool 30 is extended to connect with the male half of hydraulic connector 58 on clamp assembly 51, the seals between hubs 15 and 21 are then tested for pressure integrity. A suitable hydraulic connector 58 may be that disclosed and claimed in U.S. Pat. No. 3,918,485 by R. A. Weber et al. After a good pressure test and on command from the surface connecting tool 30 opens manual isolation valve 16 and releases latch fingers 65 from spool piece 19. The tool is retrieved to the surface, guidelines are retrieved and the connection is complete.
To retrieve a spool piece for replacement, connecting tool 30 is lowered and latched onto the installed spool piece 19. Spool piece 19 is disconnected from the manifold and pipeline hubs by operation of torque motors 79 to release clamp assemblies 50 and 51 and by operation of piston-cylinder assemblies 39 and 43 to move guidance frame 40 and landing frame 41 to spread the manifold and pipeline hubs. The wobble plate assembly 34 is centered and spool piece 19 is lifted from between the hubs and connecting tool 30 is retrieved.
In U.S. Pat. No. 3,775,986 entitled "Method and Apparatus of Making Remote Pipeline Connections" a "pull-in" method to align subsea pipelines is disclosed and claimed. The method of the present invention for connecting the pipeline hub to the spool piece hub may also be used with that "pull-in" method once the pipeline hub and spool piece hub are properly positioned and aligned.
Spool piece 19 may be, as described, a valve spool or it may be a pipe, control pod or any other maintainable component. Also, the method for connecting the pipelines may be conducted from a floating vessel or grounded platform. Further, instead of guidelines to guide the trunnion assembly and connecting tool into proper position other known guiding techniques, such as the acoustic positioning technique, may be used. Other changes and modifications may be made in the illustrative embodiments of the invention shown and/or described herein without departing from the scope of the invention as defined in the appended claims.
|
A subsea pipeline hub is connected to the hub of an adjacent spool piece connected to an in-place manifold of a subsea structure used in the production of oil and/or gas. The pipeline hub is positioned relative to the opposing spool hub and a remotely operated pipeline connecting tool is lowered from the water's surface to the subsea structure using guidelines and structural guidance for alignment of the pipeline hub with the spool piece hub. The spool piece hub is then drawn to the pipeline hub and the hubs are clamped together by operation of the connecting tool. The seal in the connection can be tested by means of the connecting tool. The spool piece may be retrieved and replaced by the connecting tool if maintenance is needed. Connecting tool operations are powered by hydraulic fluid and controlled from the surface. The pipeline hub may be lowered vertically and pivoted into its position adjacent the spool piece or may be pulled into that position.
| 5
|
[0001] This application is a division of our co-pending U.S. patent application Ser. No. 10/957,308 filed Oct. 1, 2005.
FIELD OF THE INVENTION
[0002] The invention relates to machines and methods for trimming plastic from blow molded plastic bottles.
DESCRIPTION OF THE PRIOR ART
[0003] Blow molded plastic bottles include neck flash formed at the parting lines of the molds adjacent the bottle neck. Blow molded bottles also include a neck ring extending outwardly from the bottle neck. When two bottles are simultaneously blow molded to is form a two-bottle log, neck flash and the neck ring joining the bottle necks must be trimmed away.
[0004] Conventional neck flash trimmers linearly index a lead bottle of a series of bottles to a stationary punching station where the bottle is held stationary while the flash is trimmed away. After trimming, the bottle is released, moved downstream and a new bottle is indexed to the station.
[0005] A neck ring is conventionally trimmed from the neck of a blow molded bottle by rotating the bottle and moving the neck along a cutter which severs the ring from the neck. Alternatively, the ring may be cut away by a guillotine type blade with the top of the neck machined by a rotating spindle to provide a desired finish.
[0006] Conventional neck flash trimming and neck ring or moil trimming are performed slowly. Bottles must be individually captured and oriented before trimming. Guillotine-type trimming with subsequent spindle finishing of the neck creates plastic chips which can be hard to remove from the bottle.
[0007] Conventionally, blow molded logs are trimmed using a first machine for removing neck flash and a second machine for removing neck rings. Auxiliary conveyors move logs to and between the machines. Conventional trimming machines occupy considerable space on the floor of a blow molding facility.
SUMMARY OF THE INVENTION
[0008] The invention is an improved compact high-speed bottle trimmer and method for rapidly removing neck flash and neck rings from blow molded plastic bottles. The machine feeds the molded two-bottle logs at a high uniform speed along a path wound around a number of rotating wheels while punching away neck flash and spinning the logs to cut away neck rings between adjacent bottles. Neck flash is punched away by punch assemblies which move down the path with the log during punching.
[0009] The neck rings joining the necks of the two bottles in the log are spin trimmed by spinning the logs as they move along the path and bringing the logs into engagement with two cutters. The logs are spun first in one direction and then in a reverse direction during cutting. The logs are spun around the neck axis which may be located off center, closer to one side of the bottles than the other side of the bottles.
[0010] The continuous path along which the logs are fed winds around a number of rotary wheels cantilevered outwardly from a support wall. Star wheels, having an axial width approximately equal to the length of the logs, transport the logs from an infeed conveyor to a neck flash trim wheel, from the neck flash trim wheel to a spin trim wheel and from the spin trim wheel to a discharge conveyor. All of the wheels move the logs along the path at the same circumferential speed. The logs extend across the path and are moved transversely along the path.
[0011] The position of the logs on the path is controlled during pick up of the logs from the infeed conveyor, rotation around the wheels and transfer between wheels. Accurate location of the logs facilitates accurate punch removal of neck flash and accurate removal of neck rings by spin trimming.
[0012] Continuous feeding of logs along the path permits high-speed trimming of neck flash and neck rings from the logs. The disclosed is machine has a design trim capacity of 200 logs per minute with an output of 400 trimmed bottles per minute. If desired, the throughput of the machine may be doubled without increasing the size of the machine. The machine is compact and takes up less floor space than conventional trimming machines.
[0013] Other objects and features of the invention will become apparent as the description proceeds, especially when taken in conjunction with the accompanying drawings illustrating the invention, of which there are 21 sheets and one embodiment.
DESCRIPTION OF THE DRAWINGS
[0014] FIGS. 1 and 2 are side and top views of a blow molded two-bottle log trimmed by the bottle trimmer;
[0015] FIG. 3 is a top view of the log after removing neck flash;
[0016] FIG. 4 is a top view after trimming of the neck ring to form two trimmed bottles;
[0017] FIG. 5 is a front view of a high-speed bottle trimmer;
[0018] FIG. 6 is a side view along line 6 - 6 of FIG. 5 ;
[0019] FIG. 7 is a back view of the bottle trimmer shown in the direction of arrow 7 in FIG. 6 ;
[0020] FIG. 8 is a sectional view taken along line 8 - 8 of FIG. 5 ;
[0021] FIG. 9 is a view taken along line 9 - 9 of FIG. 5 ;
[0022] FIG. 10 is a view taken along line 10 - 10 of FIG. 5 ;
[0023] FIG. 11 is a view taken along line 11 - 11 of FIG. 10 ;
[0024] FIG. 12 is a sectional view taken along line 12 - 12 of FIG. 10 ;
[0025] FIG. 13 is a sectional view taken generally along line 13 - 13 of FIG. 11 ;
[0026] FIG. 14 is a front view of a punch trim assembly;
[0027] FIG. 15 is a view along line 15 - 15 of FIG. 14 ;
[0028] FIG. 16 is a view like FIG. 14 showing the punch assembly fully collapsed;
[0029] FIG. 17 is a sectional view along line 17 - 17 of FIG. 16 ;
[0030] FIG. 18 is a sectional view along line 18 - 18 of FIG. 17 ;
[0031] FIG. 19 is a top view of a spin trim assembly;
[0032] FIG. 20 is a view taken in the direction of arrow 20 in FIG. 19 ;
[0033] FIG. 21 is a sectional view taken along line 21 - 21 of FIG. 19 ;
[0034] FIG. 22 is a view similar to FIG. 20 with a two-bottle log held in the spin trim assembly;
[0035] FIG. 23 is a sectional view taken generally along line 23 - 23 of FIG. 22 ;
[0036] FIG. 24 is a sectional view along line 24 - 24 of FIG. 23 ;
[0037] FIG. 25 is a front view of the spin trim wheel;
[0038] FIG. 26 is a partial sectional view illustrating a control for vacuum seating a bottle in a nest and pressure ejecting the bottle from the nest; and
[0039] FIG. 27 illustrates the path of movement of a log through the trimmer.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0040] High-speed bottle trimmer 10 accurately and reliably removes neck flash and bottle rings from blow molded two-bottle logs where the neck axes are offset to one side of the center of the log.
[0041] FIGS. 1 and 2 show a two-bottle log A as ejected from a blow molding machine with tail flash removed. The log A includes two blow molded bottled B having necks C located on an axis D offset to one side of the sides of the bottles. Neck ring E extends between the two necks C. Neck flash F extends in the recess between the bottles to one side of the necks and ring. Neck flash G extends between the bottles in the recess to the opposite side of the necks and ring.
[0042] FIG. 3 illustrates log A with neck flash F and G trimmed away. FIG. 4 illustrates the log with neck ring E trimmed away to separate bottles B and complete the trimming operation.
[0043] High-speed bottle trimmer 10 includes a frame 12 having a base 14 mounted on a workspace floor and a vertical mounting wall 16 extending above one side of the base and running along the length of the base, as illustrated in FIGS. 5 and 6 . The wall includes a front mounting plate 18 and end and top plates defining a rectangular recess 20 behind plate 18 .
[0044] Infeed star wheel 22 , neck flash trim wheel 24 , intermediate star wheel 26 , spin trim wheel 28 and discharge star wheel 30 are cantilever-mounted on wall 16 and extend outwardly from the wall overlying base 14 . See FIG. 6 . Infeed screw conveyor 32 is mounted on base 14 under infeed star wheel 22 . Discharge conveyor 34 is mounted on base 14 under star wheel 30 . The conveyors and wheels are driven by electric drive system 36 located principally in recess 20 .
[0045] Infeed conveyor 32 includes a pair of feed screws 38 (only one illustrated) which are rotated to feed spaced flat logs A as shown in FIGS. 1 and 2 in the direction of arrow 39 for vacuum pick up by infeed star wheel 22 . As illustrated in FIG. 1 , the offset neck axis D is adjacent the downstream side of the logs.
[0046] Infeed star wheel 22 is illustrated in FIG. 8 and includes a hub 40 mounted on wall 16 and extending outwardly from the wall over base 14 . Drive shaft 42 is journaled in bearings in the ends of the hub and includes an outer end 44 extending beyond the hub and an inner end 46 extending into recess 20 . Shaft 42 is hollow with the inner end of the shaft supporting a rotary fitting 48 connected to a source of compressed air. The shaft outer end 44 is closed. The shaft supports two spaced radial nest plates 50 and a radial neck support plate 52 located between the nest plates. Each nest plate 50 supports four ninety degree-oriented vacuum nests 54 which engage the bottles of logs A transferred by wheel 22 from conveyor 32 to wheel 24 . The nests 54 on plates 50 are axially aligned so that a nest in each wheel engages one bottle of a log to rotate the log to wheel 24 .
[0047] The position of a log A in a pair of nests 54 is shown in FIG. 9 . Each nest 54 includes a flat bottom 56 and two sidewalls 58 extending upwardly from the bottom. The sidewalls have a height less than one-half the thickness of the bottles B. A vacuum cup 60 is located in the bottom of each nest plate.
[0048] The nest plates are configured to fit snuggly around the sides and edges of the bottles B in log A. Vacuum applied to cups 60 holds the log in the nest plates. The nest plates hold the logs on wheel 22 and prevent circumferential shifting of the logs. The neck support plate 52 includes a tapered circumferential edge 62 dimensioned to have a snug fit in the shallow recess H between the two ridges on the ends of the neck ring E joining the bottles in each log. Engagement between the edge of plate 52 and the neck ring orients the log A axially when held by the vacuum nests or log holders 54 . Vacuum nests 54 and plate 52 assure the log is accurately located circumferentially and axially on wheel 22 during transport from conveyor 32 to wheel 24 .
[0049] FIG. 26 illustrates a pneumatic circuit for suction cups 60 in each adjacent pair of vacuum nests 54 on wheel 22 . Compressed air from a compressed air source 64 flows through rotary fitting 48 and shaft 42 and through an opening of the shaft to a venturi 66 . The suction port of the venturi is connected to the two suction cups 60 of an aligned pair of vacuum nests 54 through pneumatic lines 68 and 70 . Only one nest 54 is illustrated. The outlet port of the venturi 66 is connected to normally opened discharge opening 72 formed in a surface lying in a radial plate 74 perpendicular to the axis of rotation 76 of wheel 22 .
[0050] When a log A is transferred from conveyor 32 to wheel 22 opening 72 is unobstructed permitting flow of compressed air through venturi 66 and drawing vacuum through the two suction cups in the two vacuum nests 54 receiving the bottles in the log. When the log is seated in the nests the cups 60 engage the sides of the two bottles and vacuum-hold the log with plate edge 62 in recess E in the nest in proper circumferential and longitudinal orientation, as previously described, during rotation of wheel 22 .
[0051] When a log held in nests 54 of wheel 22 is rotated up to the position for transfer to wheel 24 opening 72 is moved over a fixed stop plate 78 to prevent flow of compressed air through the venturi. With opening 72 obstructed, compressed air flows through lines 68 and 70 and to the two vacuum cups 60 to blow the log outwardly from the nests 54 and seat the log on adjacent vacuum nests on wheel 24 to complete transfer of the log to wheel 24 . After the transfer has been completed, continued rotation of wheel 22 moves opening 72 away from plate 78 to permit flow of compressed air through venturi 66 and reapply vacuum to vacuum cups 60 for vacuum capture of another log from conveyor 32 . Plate 78 is illustrated in FIG. 8 . Air lines associated with the vacuum cups are not illustrated.
[0052] Infeed conveyor 32 is located in trough 80 shown in FIG. 8 and indicated in FIG. 5 . Plate 82 is mounted on the piston of an air cylinder 84 attached to the bottom of the outer end of hub 40 . Extension of the piston rod moves plate 82 from a retracted position shown in FIG. 8 to a work position obstructing discharge opening 72 of the pneumatic circuit shown in FIG. 26 for the adjacent two vacuum nests 54 . During normal pick up of logs from conveyor 32 by wheel 22 cylinder 84 is retracted and plate 82 does not close discharge opening 72 . Vacuum is then applied to the vacuum cups in the nests so that the nests pick up the logs fed along the conveyor.
[0053] Machine 10 includes sensors (not illustrated) for determining whether tail flash has been trimmed from logs fed along conveyor 32 . In the event a log fed along conveyor 32 contains tail flash and actuates a sensor, cylinder 84 is extended to move plate 82 adjacent the discharge 72 for the pneumatic circuits of the nests which would pick up the log. Vacuum is not applied to the nests and the log is fed past the end of the conveyor and falls into trough 80 .
[0054] Neck flash trim wheel 24 includes a hub 86 mounted on wall 16 and hollow rotary drive shaft 88 journaled bearings in the ends of the hub. A rotary fitting 90 mounted on the inner end of the rotary drive shaft is connected to a source of compressed air which is flowed into the shaft. The outer end of the drive shaft extends outwardly from wall 16 over base 14 and is closed. Three spaced radial support plates 92 are secured to the outer end of shaft 88 above the base and extend radially outwardly from the shaft. Four ninety degree-spaced mounting plates 94 are mounted on plates 92 and extend from plate 92 nearest wall 16 outwardly from the wall and beyond outer most plate 92 . Strengthening ring 96 is mounted on the outer end of plates 94 . Two vacuum nests 98 are mounted on a plate 102 on the free end of each plate 94 in alignment with the nests 54 of wheel 22 . Vacuum nests 98 each include a bottom and sidewalls as in nests 54 and a vacuum cup in the bottom. The adjacent ends of the bottoms of the two nests slope upwardly to provide a tapered ridges 100 conforming to the inwardly sloped upper walls of bottles B in log A transferred to the nests. The nests 98 accurately align logs A circumferentially and longitudinally on wheel 24 . The vacuum cups in each pair of nests 98 are connected to pneumatic systems like the system shown in FIG. 26 to apply vacuum to the nests when the nests pick up logs from wheel 24 and to remove the vacuum and apply compressed air to the nests when the logs are transferred from the nests in wheel 24 to the nests in intermediate star wheel 26 . A bottle neck and neck ring support 104 shown in FIG. 18 extends between the two nests under the necks C and bottle ring E of log A held on the nests. The top of support 104 conforms to the ridged shape of the bottle necks and neck ring. The support or anvil 104 has a width equal to the diameter of the neck and ring. Flash discharge openings 106 and 108 are formed through plate 102 to either side of support 104 and are located above discharge opening 110 in plate 94 .
[0055] Wheel 24 includes four sets of flash punch tooling 112 with each set associated with nests 98 on one plate 94 . Each tooling 112 includes a flash punch assembly 114 located above plate 94 and a drive assembly 116 for moving the punch assembly from a retracted position where the punch assembly is away from a log held by the nests 98 and adjacent wall 16 as shown in FIGS. 11 and 12 to an extended position with the punch assembly located above the log and away from wall 16 . The drive assemblies are moved in and out by fixed cylindrical cam 118 mounted on wall 16 . The punch assemblies are actuated by fixed punch cam 120 mounted on wall 16 by rods 199 and located above the nests and punch assemblies 114 when extended.
[0056] Two slide rails 122 extend along the sides of each plate 94 from the inner most plate 92 to plate 96 . Drive assembly 116 includes a plate 124 located above the inner end of plate 94 and secured to slide rails 122 by suitable bearings for movement along plate 94 in a direction parallel to the axis of rotation of wheel 24 . The inner end of plate 124 carries a cam follower 126 fitted in cam groove 128 of fixed cylindrical cam 118 . The cross shaft for small diameter gear 130 and large diameter gear 132 is journaled in bearings located on the opposite sides of plate 124 . Small diameter gear 130 engages rack 134 on plate 94 . Large diameter gear 132 engages rack 136 on support 138 of punch assembly 114 .
[0057] The flash punch assembly 114 includes a top plate 140 and two like side plates 142 forming U-shaped support 138 . The outer end of each side plate 142 carries a bearing engaging a slide rail 122 . The inner end of each side plate carries a bearing engaging a slide rail 144 mounted on plate 116 . The flash punch assembly 114 includes a punch top plate 146 located above plate 140 , a punch lower plate or platen 148 and four guide posts 150 joining the plates together and extending through bearings in support top plate 140 . Plate 146 extends laterally beyond the sides of support 138 and is connected to two return posts 152 which extend freely through brackets 154 mounted on support side plates 142 . Springs 156 are mounted on posts 152 and confined between the top plate and the brackets. The springs bias the plates 146 and 148 toward an upper position shown in FIG. 12 with plate 148 engaging plate 140 .
[0058] Flash punches 158 and 160 shown in FIG. 13 are mounted on the bottom of punch bottom plate or platen 148 . Punch 158 is shaped to punch neck flash F from a log A held on nests 98 and support 104 and punch 160 is shaped to punch neck flash G from the log.
[0059] Top plate 146 supports roller cam follower 162 which is engageable with fixed punch cam 120 for moving the punches from a retracted position through a punch stroke to an extended position and, in cooperation with springs 156 , for returning the punches back to the retracted position above a log A held on the vacuum nests.
[0060] Fixed punch cam 120 is illustrated in FIGS. 14 and 15 . Rotation of wheel 24 moves successive flash punch tooling 112 in the extended position shown in FIGS. 17 and 18 past cam 120 . Roller cam follower 162 engages surface 164 of the cam to move punches 158 and 160 inwardly and trim neck flashes F and G from a log held on the vacuum nests and anvil. After the punch stroke has been completed, springs 156 hold the follower against the continuation of cam surface 164 during an outward or return stroke. Stop 166 on support top plate 140 limits downward movement of the punches. Severed neck flash falls into the interior of wheel 24 for gravity delivery through chute 168 to trough 80 . In the event the punch tooling is not returned by the springs rotary follower 170 on top plate 146 engages retraction cam 171 which returns the punches and plates to the retracted position with the punches above the log held on the nests. Additionally, cam 120 is spring loaded in case the tooling 112 jams and prevents lowering of punches 158 and 160 by the cam. In that event, the cam pivots upwardly out of the path of movement of follower 162 and trimmer 10 is shut down.
[0061] During transfer of a log A from wheel 22 to 24 , as shown in FIG. 2 , the flash punch assembly 114 is retracted adjacent wall 16 out of the path of movement of wheel 22 . After the log has been vacuum transferred from the nests of wheel 22 to the nests of a tooling assembly on wheel 24 the cam follower 126 for the tool assembly is rotated along a rise portion 172 of cam groove 128 to move the punch assembly to the extended position over the log A held on the vacuum nests before engagement with cam 120 . Movement of the punch assembly from the retracted to the extended position is delayed until the assembly has been rotated away from wheel 22 . See FIG. 6 . As follower 126 moves along rise portion 172 plate 124 is moved outwardly from wall 16 , gear 130 is rotated in rack 134 to rotate large gear 132 and rapidly move rack 136 and support 138 from the retracted to the extended position. Continued rotation of wheel 24 moves follower 126 along dwell portion 174 of groove 128 to hold the punch assembly in the extended position during movement past cam 120 and punching of neck trim from the log. After punching has been completed and assembly 112 has moved away from cam 120 the follower 126 moves down a fall portion of groove 128 to move the punch assembly 114 back to the retracted position.
[0062] Intermediate star wheel 26 transfers flash-trimmed logs A from the flash punch tooling assemblies 112 of wheel 24 to spin trim tooling assemblies 176 on spin trim wheel 28 . Wheel 26 includes four sets of axially spaced vacuum nests 178 , like nests 54 of wheel 22 and is otherwise like wheel 22 as previously described. Both wheels 22 and 26 are rotated in a counterclockwise direction as viewed in FIG. 5 . Each wheel has four ninety degree-oriented sets of vacuum nests.
[0063] The vacuum nests of wheel 26 are provided with pneumatic circuitry as shown in FIG. 26 to facilitate vacuum capture of logs from wheel 24 and air jet release of logs to wheel 28 .
[0064] Spin trim wheel 28 includes four ninety degree-spaced spin trim tooling assemblies 176 each mounted on a mounting plate 180 , like plates 94 in wheel 24 , and facing outwardly from the plate. Each plate 180 is mounted on three radially support plates 182 , like plates 92 in wheel 24 , which are in turn supported by a drive shaft mounted for rotation in a hub on wall 16 . A fixed cylindrical cam 184 , like cam 118 in wheel 24 , surrounds the drive shaft for wheel 28 between the inner most plate 182 and wall 16 .
[0065] Each assembly 176 includes two like spin units 190 each having a hollow housing 192 mounted on plate 180 with a slide body 194 located in the housing and extending above the housing. The slide bodies have limited longitudinal movement within the housings in a direction parallel to the axis of rotation of wheel 28 . In FIGS. 19-21 the bodies are separated. In FIG. 22 the bodies are moved together to capture a log. The slide bodies are held in the housings on rods 196 extending through the bodies and the ends of the housings.
[0066] Screw nut 198 is mounted on guide rails on the inner end of plate 180 , adjacent wall 16 . A cylindrical cam follower 200 is mounted on the screw nut and is fitted in cam groove 202 extending around cam 184 . The screw nut includes a rotary output shaft 204 which is connected to rotary drive shaft 206 extending through both spin units 190 . A drive gear 208 is mounted on shaft 206 on the outside of each spin unit as shown in FIG. 21 . Each gear 208 engages an idler gear 210 mounted on shaft 212 extending through assembly 190 and a driven gear 214 mounted on shaft 216 extending through the upper portion of a slide body 194 , above housing 192 . In each spin unit 190 , a bottle retention cup or log holder 218 is mounted on the inner end of each shaft 216 and faces the bottle retention cup 218 on the other spin unit 190 . Each cup 218 includes a rectangular recess 230 dimensioned to be extended over the bottom I of a flash-punched log A positioned by wheel 26 between the cups when retracted as in FIG. 21 . The cups each include a ledge 232 extending outwardly from the recess to 230 for supporting the log when placed between the open or retracted cups.
[0067] Each assembly 176 includes a bottle neck support 234 for the necks C of the bottles in the log in the assembly. The neck support is mounted on plate 180 and includes a pair of support rollers 236 located under the neck of each bottle in the log held in the assembly so that the bottle necks and the neck ring joining the bottle necks are supported as shown in FIGS. 23 and 24 . The tops of the necks and the neck ring extend above the rollers to permit spin trimming of the ring away from the necks.
[0068] Shafts 216 rotate bottle retention cups 218 . As shown in FIG. 19 , the recesses 230 in which the bottoms of the bottles in log A are seated are offset to one side of the shafts 216 . When log A is held in cups 218 , the neck axis D of the log coincides with the axis of shafts 116 . Rotation of the shafts rotates the log about offset axis D for cutting away of neck ring E.
[0069] Trimmer 10 may be used to trim neck flash and neck ring from logs having bottles with the bottle necks located equidistant between the bottle sides, rather than offset. In this case, the anvils and punches of tooling 112 would be located centrally. In assembly 176 the recesses 230 would be located centrally with regard to neck support 234 , rather than offset as shown in FIG. 19 .
[0070] The screw nut 198 , drive shaft 206 , gears 208 , 210 and 214 and shaft 216 form a drive 238 for rotating a bottle or log retention cups 210 during trimming away of neck ring E. Drive 238 is actuated by fixed cam 184 .
[0071] Cup opening and closing drive 240 is operated by fixed cams on plate 186 . The drive includes cam follower support 242 located on the end of assembly 186 away from wall 16 and mounted on the outer ends of two shift rods 244 . Each rod is mounted on one end of support 242 and extends longitudinally along the assembly 176 past the outer spin assembly 190 and to inner assembly 190 . See FIG. 20 . The rods extend through rod supports 246 mounted on plate 180 . A block 248 is attached to the inner end of each rod 244 and supports a link 250 which is connected to the slide body in the inner unit 190 through opening 252 formed in housing 192 . A block 254 is attached to each rod 244 adjacent the outer unit 190 and is connected to the lower end of pivot arm 256 by link 258 . The upper end of the pivot arm is connected to link 260 which in turn is connected to the slide body 194 in housing 192 through opening 262 . The center of the pivot arm 256 is pivotally mounted on housing 192 .
[0072] FIGS. 19-21 show assembly 176 with cups 218 spaced apart in an open position. Cam follower support 242 is located in an inner position. Movement of the support 242 outwardly, away from wall 16 , moves rods 244 outwardly. The slide body 194 in the inner or distal spin unit 190 is pulled outwardly by outward movement of links 250 . The slide body in the outer or proximal spin unit 190 is pushed inwardly the same distance the other slide body is pulled outwardly by rotation of pivot arms 256 and inward movement of links 260 . During movement of the slide bodies toward each other gears 214 slide along idler gears 210 while retaining engagement with the idler gears. The closing movement of the two cups 218 moves recesses 230 onto the ends of a log A supported on ledges 232 to capture the log in assembly 176 with log axis D aligned with the axis of shafts 216 which rotate the cups and log. See FIGS. 22 and 24 .
[0073] Rotary cam follower 264 is located on the center of support 242 between rods 244 and faces outwardly toward plate 186 . Follower 264 engages a rotary cam 266 on plate 186 to move the cups from the closed, log-engaging position shown in FIG. 22 to the open position of FIGS. 19 and 20 permitting placement or removal of logs between the cups.
[0074] Spring 268 , shown in FIG. 19 , is attached between follower support 242 and support 246 mounted on the outer end of plate 180 . The spring 268 is compressed and biases the support 242 outwardly, away from wall 16 to position cups 218 together in a closed position holding a log in place on assembly 176 with log axis D aligned with the spin axis of shafts 216 .
[0075] Support 242 carries a second follower 270 and plate 186 carries a second fixed cylindrical cam 272 located between follower 270 and plate 180 . During normal operation of assemblies 176 spring 268 moves the cups together to capture logs and cam 272 performs no work. Cam 272 moves the cups together if spring 268 fails to close the cups.
[0076] Two-blade cutter assembly 274 is mounted on wall 16 and partially surrounds wheel 28 , as shown in FIG. 25 . Logs trimmed with neck flash removed are delivered to assemblies 176 in wheel 28 in the gap 276 between the ends of the cutter assembly. The assembly cuts away the neck rings E of the logs carried by spin trim assemblies 176 . The resultant individual bottles are delivered from assemblies 176 to vacuum nests of takeaway wheel 30 .
[0077] FIG. 24 illustrates the position of a log A, with neck flash previously trimmed away, held between closed cups 218 during spin trimming. Assembly 274 includes circumferential plates 278 , 280 which extend nearly completely around wheel 28 leaving gap 276 . Each plate 278 , 280 includes an inner hold down edge 282 which engages the neck C of a bottle B held in assembly 176 . During spin trimming, each bottle B in log A is held in place by a cup 218 , two support rollers 236 and one edge 282 .
[0078] Cutter assembly 274 includes two circumferential cutting blades 284 having sharpened inner edges 286 which engage and spin cut the logs held in assemblies 176 at the junctions between the bottle necks B and neck ring E.
[0079] A log held in vacuum nests on wheel 26 is rotated between open bottle retention cups 218 of one of the rotating assemblies 176 of wheel 28 . When the log is in place, cam follower 264 is rotated to a fall surface on cam 266 and spring 268 moves cups 218 together to seat the ends of the bottles in recesses 230 . At the same time, the vacuum holding the bottles in the nests on wheel 26 is reversed and compressed air is flowed through the suction cups in the nests to release the log from the vacuum nests. Rotation of wheel 28 moves the confined log under hold down surfaces or edges 282 of plates 278 , 280 to confine the bottle necks between rollers 236 and the plates. Rotation of wheel 28 moves cam follower 200 along a sloped surface in cam groove 202 to drive screw nut 198 outwardly from wall 16 along shaft 204 to rotate the shaft so that the drive shaft 216 , cups 218 and held log A are spun around neck axis D two revolutions in a first direction. The cam follower 200 then is moved along a reverse slope section of cam groove 202 to retract the screw nut and spin the log A on assembly 176 two revolutions in a second, reverse direction.
[0080] Rotation of assembly 176 holding the log and spinning of the log as the log is rotated around wheel 28 moves the neck portions of the spinning log into engagement with cutting edges 286 of blades 284 to trim the neck ring E from the two bottles B.
[0081] In the embodiment disclosed, screw nut 198 spins log A two revolutions in each direction as the log is spun in engagement with blades 284 . The number of rotations per inner and outer stroke of the nut screw may be adjusted as required. Additionally, the shape and lead end of edges 286 may be adjusted as required for optimum cutting away of the neck ring. The blades may be brought into gradual engagement with the sides of the bottle neck for gradual cutting as the bottles are spun along the cutting blades. Alternatively, the blades may include a portion which initially punctures the thickness of the bottle necks and then cuts the entire thickness of the neck is spun around axis D.
[0082] The log is held in a known position in cups 218 . The thickness of the plastic at the part lines extending across the neck ring may vary. The cutting edges 286 may have a geometry selected for optimum cutting of the plastic at the bottle necks dependent upon circumferential variation in thickness of the plastic.
[0083] FIG. 7 illustrates the drive system 36 for trimmer 10 . The system includes an electric motor 288 connected to a transmission 290 mounted on wall 16 . The transmission has an output shaft supporting pulleys adjacent the wall and remote from the wall. Drive belt 292 engages a pulley on the output shaft and pulley 294 mounted on the inner end of drive shaft 88 for wheel 24 . Drive belt 296 engages a second pulley 298 on the inner end of shaft 88 and pulley 299 on the inner end of the drive shaft for wheel 28 .
[0084] Belt 309 is wound around a pulley mounted on the transmission output shaft, drive pulley 302 on drive shaft 42 for wheel 22 and a take off pulley 311 for the infeed screw conveyor drive. Belt 300 is wound around a second pulley 306 on the inner end of the drive shaft 42 and pulley 306 on the inner end of the drive shaft for wheel 26 . Belt 304 is wound around a second pulley on the drive shaft for wheel 26 and small diameter pulley 308 on the drive shaft for wheel 30 .
[0085] Infeed conveyor 32 is driven by belt 309 . Discharge conveyor 34 is driven by belt 310 and rotary shaft drive 314 extending across the back of wall 16 under the motor and transmission.
[0086] The pulleys on the inner ends of the drive shafts for wheels 22 , 24 , 26 and 28 are the same diameter. Each of these wheels carries four ninety degree-spaced assemblies or vacuum nests and rotates at the same speed, although as illustrated in FIG. 5 , wheels 22 and 26 rotate counterclockwise and wheels 24 and 28 rotate clockwise. Wheel 30 carries three sets of vacuum nests. The pulley 308 for rotating wheel 30 is smaller than the pulleys rotating the other wheels and rotates wheel 30 at a speed one-third faster than the speed of rotation of other wheels so that the vacuum nests on wheel 30 capture trimmed bottles delivered from wheel 28 having four spin trim assemblies 176 .
[0087] The operation of bottle trimmer 10 will now be described by describing the operations performed on a log A placed on infeed conveyor 32 after tail flash has been removed from the ends of the two bottles in the log.
[0088] Conveyor 32 conveys log A downstream at a speed which locates the log under a pair of vacuum nests 54 on wheel 22 . The wheel rotates to position the nests over the two bottles in the log as illustrated in FIG. 1 . Compressed air is flowed through the circuit of FIG. 26 for the nests to draw vacuum through cups 60 and vacuum-hold the log in the nests. The log is held accurately in place by the nests and edge 62 .
[0089] The infeed conveyor 32 includes sensing means (not illustrated) to detect untrimmed tail flash on log A. In the event tail flash has not been trimmed from the log, air cylinder 84 is shifted to close the discharge opening 72 for the pneumatic system for the nests so that compressed air is flowed through the vacuum cups and the log is not captured in the nests, remains on the infeed conveyor and is discharged into trough 80 .
[0090] A log held in vacuum nests in the wheel 22 is rotated counterclockwise as shown in FIG. 5 up to wheel 24 and is transferred from nests 54 on wheel 22 to nests 98 on wheel 24 . The two nests are rotated together at the 12 o'clock position for wheel 22 and the 6 o'clock position for wheel 24 . Compressed air is blown through the vacuum cups of nests 54 and vacuum is applied to nests 98 at transfer. As illustrated in FIG. 8 , the flash punch assembly 114 associated with nests 98 receiving the log is in the retracted position adjacent wall 16 and out of the path of movement of wheel 24 during transfer of the log. After transfer of the log to vacuum nests at the 6 o'clock position on wheel 24 , continued clockwise rotation of the wheel rotates the log and moves cam follower 28 along a rise surface of fixed cam 118 to actuate drive assembly 116 and move flash punch assembly 114 from the retracted position of FIG. 12 to an extended position where punches 158 and 160 are located above the neck portion of the log. The flash punch assembly is fully extended before the wheel rotates the assembly into engagement with cam 120 .
[0091] As the wheel continues rotation in a clockwise direction, follower 162 engages surface 164 of cam 120 to lower punches 158 and 160 and trim flash F and G from log A. As shown in FIG. 16 , neck flash is trimmed from the log when the log is located at the upper portion of the path extending partially around wheel 24 . The trimmed flash gravity falls into the hollow interior of wheel 24 . The punches 158 and 160 rotating on wheel 24 and move downstream along the path of movement of the log during punching. Chute 168 extends into the interior of the wheel, receives the trimmed flash and guides the gravity-fall of the flash into trough 80 .
[0092] After punching, continued rotation of wheel 24 moves follower 162 down cam surface 164 to raise the punches above the log. When punch assembly 114 has been rotated clear of the cam a fall surface on cam 128 retracts the flash punch assembly from the extended position to the retracted position before wheel 28 rotates the flash-trimmed log to position for transfer to vacuum nests 178 of wheel 26 . Vacuum is supplied to nests 178 and compressed air is flowed through the vacuum cups of nests 98 to complete the transfer.
[0093] The flash-trimmed log is carried by nests 178 on wheel 26 to gap 276 between the ends of the cutter assembly 274 partially surrounding wheel 28 . When moved into the gap the log is seated between two separated or open bottle retention cups 218 of a spin trim assembly 176 . The log rests on ledges 232 . The neck C of each bottle rests on two rollers 236 . See FIGS. 19-21 . Immediately after wheel 26 positions the log A on assembly 176 rotation of wheel 28 moves cam follower 264 down a fall surface of cam 266 so that spring 268 moves the bottle retention cups 218 together to capture the ends of the bottle and hold the bottle for spin trimming. Upon continued rotation of wheel 28 neck C of each bottle in the log is held between two rollers 236 and the hold down surface 282 of one of plates 278 and 280 . After the log has been captured as described, follower 200 moves down a surface in cam groove 202 to move screw nut 198 first away from wall 16 and then back toward wall 16 to spin the log first two revolutions about axis D in a first direction and then spin the log back two revolutions about the axis in the opposite direction. Trimming occurs as wheel 28 rotates the log along edges 286 of blades 284 to sever neck ring E from bottle necks C. After the neck ring has been severed, the individual trimmed bottles B are held in place on the spin trim assembly 176 between cups 286 and rollers 236 and plates 278 and 280 .
[0094] After spin trimming continued rotation of wheel 28 moves the trimmed bottles into engagement with vacuum nests 312 on wheel 30 . Follower 264 rides up a rise surface on cam 266 to retract or move apart cups 218 and release the trimmed bottles after the bottle necks have moved past the downstream ends of plates 278 and 280 . The released bottles are vacuum drawn into nests 312 and are rotated by wheel 30 down onto takeaway conveyor 34 . When above the conveyor, vacuum is released and compressed air is blown through the suction cups to transfer the bottles from the nests 312 to the conveyor for takeaway as illustrated.
[0095] Bottle trimming machine is designed to operate at a high production speed of about 200 logs per minute with an output of 400 trimmed bottles per minute. The machine accurately holds the logs and bottles in place on each of the wheels during movement of the logs, and subsequently trimmed bottles, along a continuous arcuate path 320 at a constant speed. FIG. 27 illustrates the path of movement of log A from infeed conveyor 32 to discharge conveyor 34 .
[0096] Arcuate path 320 extends from infeed end 322 where the log is picked up by wheel 22 from conveyor 32 and extends continuously around arcuate portions 324 , 326 , 328 , 330 and 332 on wheels 22 , 24 , 26 , 28 and 30 respectively to discharge point 324 where the trimmed bottles are placed on discharge conveyor 34 . Wheels 22 , 24 , 26 and 30 support the logs and bottles in nests or in spin trim assemblies located a distance r from the axis of rotation of the wheel. Wheels 22 , 24 , 26 and 28 are rotated at the same circumferential speed so that the logs are moved along path 320 at the same speed. The radius of wheel 30 is less than r. Accordingly, wheel 30 is rotated more rapidly than the other wheels so that the trimmed bottles carried by wheel 30 are moved along the downstream portion of the path 320 at the same speed the logs are moved along the portion of the path upstream from wheel 30 . The logs are held on the wheels 22 , 24 , 26 and 28 with the neck axes D extending transversely to the direction of movement along path 320 and parallel to the rotational axes of the wheels. The neck axes of the bottles carried by wheel 30 parallel the axis of the wheels.
[0097] The punches 158 and 160 in flash punch assembly 112 move along the path with the logs during punching or trimming away of neck flash. In disclosed machine 10 , the flash punch assemblies 114 are retracted away from the logs when the logs are transferred from wheel 22 to wheel 24 . Then, the punch assemblies are extended parallel to the axis of rotation of wheel 24 and perpendicular to the path 320 to a position over the logs where neck flash is trimmed away from the logs.
[0098] If desired, wheel 24 could be modified to have flash punch assemblies which are permanently located in the position of the retracted punch assemblies of machine 10 disclosed herein and the wheel could include drive assemblies which shift the vacuum nests 98 holding the logs in place across the path in a direction parallel to the axis of rotation of the wheel to position the logs under the punch assemblies for trimming. After trimming, the trimmed logs would be shifted back to their original positions for transfer to wheel 26 . During such a punching operation, the logs are moved downstream along path 320 at a continuous speed but are shifted laterally, punched and then shifted back.
[0099] As the logs are rotated along the path on wheel 28 the logs are spun along the neck axis and engage fixed cutting blades to trim away neck rings between the bottles in the log. Spin trimming of the neck rings is preformed without altering the movement of the logs, and then bottles, along the path.
[0100] The vacuum nests on wheels 22 , 24 and 26 accurately locate the logs on the wheels during continuous movement along the path. Spin trim assemblies 176 accurately locate the logs during movement around wheel 28 . Finally, vacuum nests 312 on wheel 30 accurately locate the trimmed bottles on wheel 30 during transport from wheel 28 to the discharge conveyor 34 .
[0101] A set of four vacuum nests or log holders 54 is provided on wheel 22 . A set of four vacuum nests or log holders 98 is provided on wheel 24 . A set of four vacuum holders or nests 178 is provided on wheel 26 . A set of four pairs of cup holders or log holders 218 is provided on wheel 28 . A set of three vacuum nests or log holders 312 is provided on wheel 30 . During downstream movement of logs along path 320 the log holders on each wheel are repetitively moved downstream along the second of the path defined by the wheel and carry logs downstream along the path. The wheels move the logs continuously downstream along the path during trimming as described. Each wheel 22 , 24 , 26 , 28 and 30 is a feed conveyor which repetitively moves logs downstream along its respective portion of the path. Accurate location of the logs on the wheels assures that flash trimming and spin trimming is performed at proper locations on the logs and improves the quality of the trimmed bottles. Trimmed bottles are discharged at regularly spaced known intervals on discharge conveyor 34 in position for downstream operations.
[0102] The wheels 22 , 24 , 26 , 28 and 30 are cantilevered on wall 16 and extend outwardly from the wall. This arrangement permits the compact machine design and facilitates worker access to the wheels and to drive system 36 during set up and servicing. Path 320 with joined counterclockwise and clockwise sections is compact and reduces the size of the trimmer and auxiliary conveyors.
[0103] Wheels 22 , 24 , 26 and 28 have four ninety degree spaced stations. If desired, the throughput of the machine may be increased by doubling the number of stations on each wheel without appreciably increasing the size of the machine. Doubling the stations would increase the throughput from 200 logs per minute to 400 logs per minute and 800 bottles per minute.
[0104] In wheel 24 the punch tooling for removing neck flash moves down along the path 320 with the logs, permitting extension of the tooling for trimming flash without slowing movement of the logs along the path or requiring special alignment of the logs. Spin trim assemblies 176 on wheel 28 rotate around the wheel at the same speed of the logs permitting capture and spinning of the logs for spin trimming without altering downstream movement of the logs along the path.
[0105] Continuous downstream movement of the logs during trimming facilitates high-speed operation of machine 10 . There is no need to stop movement of the logs or reorient the logs in a known position before trimming. Indexing of individual logs is eliminated.
[0106] Machine 10 has been described in connection with trimming of plastic from two bottle logs. If desired, the machine may be used to trim neck flash and neck rings from single body logs using single vacuum nests and tooling for single bottle logs rather than two bottle logs. The single bottle logs trimmed by the machine may have necks located to one side of the bottle, like bottle B, or centrally located necks.
[0107] While we have illustrated and described a preferred embodiment of our invention, it is understood that this is capable of modification, and we therefore do not wish to be limited to the precise details set forth, but desire to avail ourselves of such changes and alterations as fall within the purview of the following claims.
|
An apparatus for cutting a plastic blow molded body ejected from a blow mold, the apparatus includes spaced holders rotatable about a common axis. Each holder receives an end of a plastic body. A first drive rotates the holders about the axis. A second drive moves the holders and plastic body against a trim knife to cut the body. The holders start and stop rotation with the body at a predetermined orientation with respect to the common axis.
| 1
|
REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of copending application, Ser. No. 496,322, filed May 19, 1983.
BACKGROUND OF THE INVENTION
This invention relates to improvements in high pressure mechanical seal assemblies constructed and used to prevent the uncontrolled leakage of a liquid along a rotating shaft, as for example, leakage along the shaft of a rotary liquid pump.
The present invention was developed especially for use with nuclear reactor coolant pumps, boiler recirculating pumps, boiler feed pumps and pipeline pumps, and will meet the requirements for extreme and widely changing conditions of pressures and temperatures encountered in these uses, it being understood that the present invention can also be used in less demanding installations. As an example of the widely changing pressures and temperature, the normal operating pressure in a pressurized water reactor is about 2200 psig, and during start-up, the pressure can be as low as 20 to 30 psig. In such reactor, the water in a coolant loop can reach a temperature of about 600° F., while the water entering the seal area may be as low as about 80° F. In these pumps, the pump shaft may move axially and may also wobble or deflect radially. An additional rigorous operating condition for the seals in such application is the combination of high pressure and high surface speeds which result from large diameter parts. It is thus necessary to construct a mechanical seal assembly capable of performing under these operational conditions.
Mechanical seal assemblies usually comprise the combination of a rotatable seal ring connected to a rotatable shaft for rotation therewith and a non-rotatable or stationary seal ring connected to the flange of a housing. Each seal ring has a radial seal face and the seal faces oppose one another. Whether or not the seal faces engage one another is debatable because there is usually a film of fluid therebetween providing lubrication for the rotation of one of the faces. In many seal assemblies, one or more coil springs urge one of the rings toward the other, so that in reality, one or both of the seal rings are capable of limited axial movement, even though they are commonly referred to as "rotatable" or "stationary". Multiple stage seal assemblies comprising a plurality of seal assemblies are known in the art.
DESCRIPTION OF THE PRIOR ART
In Martinson U.S. Pat. No. 4,272,084, a multiple stage mechanical seal assembly is described. The rotatable seal ring of each stage is connected by axial pins to a flange on a sleeve which, in turn, is connected to the rotatable shaft. Each stage has its own sleeve. The stationary seal ring of each stage is sealed to a carrier which is connected to a housing by an encircling elastomeric O-ring confined by a retainer ring and snap rings. A plurality of coil springs urge the stationary ring toward the rotatable ring in each stage. Each spring is received in a spring pocket, a part of which is in the carrier and a part of which is in the housing. No spring retainers are used.
U.S. Pat. Nos. 2,444,713, Solari, 2,498,739, Magnesen, 2,559,964, Jensen, 2,653,837 and Voytech, teach, in mechanical seal assemblies, the use of resilient rings to connect one of the seal rings to either a shaft or a housing.
Kime et al, U.S. Pat. No. 4,094,513, and Kropp, U.S. Pat. No. 4,202,553, both teach multiple stage mechanical seal assemblies including a fixed and stationary, cylindrical member surrounding a shaft with spring pockets therein, some pockets facing one way and some pockets facing the opposite way. Each spring facing in the same direction urges one seal ring of a stage toward the other ring of the same stage.
SUMMARY OF THE INVENTION
The mechanical seal assembly of this invention is capable of performing its intended function under the widely adverse operating condition, and can be used singly or in multiple stages. The seal assembly is especially adapted for use in horizontal or vertical pumps, of the type previously described.
The seal assembly of this invention comprises a stationary seal ring and a rotatable seal ring having opposed faces, one ring is urged toward the other ring. The stationary seal ring is usually made of carbon and the rotatable seal ring is made of a harder material, such as titanium carbide, aluminum oxide and the like. The complete seal assembly is mounted on a shaft sleeve, so that it can be pre-assembled and then axially positioned on the shaft at the proper operating location.
The stationary carbon seal ring is sealed, by spaced O-rings, to an encircling metal retainer. Also at least a portion of a face of the ring is covered by a radially inwardly directed flange on the retainer. Because the inside diameter of the stationary field ring is exposed to the lower pressure fluid and the retainer is exposed to the higher pressure fluid, the retainer substantially eliminates severe radial deflections of the carbon seal ring which could be caused by extreme pressure differentials on the inside and outside of the ring. The stationary seal ring is supported on a "balance" sleeve means surrounding and spaced from the shaft sleeve. The balance sleeve permits some angular movement or wobbling of the shaft so as to eliminate adverse effects of shaft misalignment which frequently occurs in pumps of the type described.
The rotating seal ring of the assembly is resiliently connected to the rotating shaft (or sleeve, as the case may be) by transversely positioned elastomeric keys which fit into pockets formed by transverse external flats formed on the seal ring and transverse grooves cut into the inside of a cylindrical lock ring. The grooves are in an axially extending portion of the lock ring which surrounds the rotating seal ring. The formation of the flats on the rotating seal ring avoids notching, and thus weakening, the seal ring to receive the usual drive pins. The lock ring prevents the rotating seal ring from flying apart in case of its failure.
The elastomeric keys provide a self-compensating feature to the seal assembly. The keys exert radially inwardly directed forces on the seal ring and when subjected to torque, the forces increase, causing the seal ring and its seal face to distort in a wavy pattern. This permits fluid flow across the seal faces and reduces the frictional forces therebetween. As torque increases, the radial forces increase and the seal face deflection increases which further reduces the frictional force between the faces.
A novel spring holder is used to position a plurality of springs to resiliently urge the stationary seal ring toward the rotatable seal ring. The spring holder is positioned in an annular cavity in the pump housing, and specifically in that part of the housing known as a seal flange. The spring holder is a ring having a radial front surface and a radial back surface with axially arranged pockets, for each receiving a coil spring. Some spring pockets open to the front surface and some spring pockets open to the rear surface. Generally the front and rear pockets are offset and evenly spaced from one another. Usually there are equal numbers of front and rear pockets. This series arrangement of springs provides a substantially uniform spring load in the stationary seal ring and permits twice the axial movement of the pump shaft as would be permitted by the susual spring arrangement wherein the springs act in one direction without affecting the function of the seal assembly. The arrangement of springs according to this invention results in a relatively short (in axial length) and compact seal assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cross-sectional view through a single stage mechanical seal assembly constructed according to this invention;
FIG. 1A is a partial cross-sectional view taken on line 1A of FIG. 1;
FIG. 2 is a perspective illustration of a spring retainer for use in a seal assembly constructed according to this invention and showing the spring pockets with springs in some pockets;
FIG. 3 is an exploded view of the rotating seal ring, the lock ring and the resilient connection therebetween; and
FIGS. 4A and 4B when laid end-to-end show a partial cross-sectional view through a multiple-stage mechanical seal assembly constructed according to this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a single stage mechanical seal assembly 10 for use with a rotatable shaft 12 and a seal flange 14 of a housing 16, the assembly 10 comprising shaft sleeve 18, rotatable seal ring 20, and stationary seal ring 22, one of which is resiliently urged toward the other. Seal rings 20, 22 have relatively rotating, opposed, and lapped faces 24, 26 across which the flow of high pressure fluid in housing 16 to lower pressure zone (at the left of FIG. 1) is substantially prevented.
Ring 20 is provided with annular flange 28, the inner defining surface 30 of which is received on flange 32 of adaptor 34. The rear of flange 28 is axially supported by O-ring 36 encircling adapter flange 32, to avoid undesirable effects of different radial deflections of ring 20 and flange 32 from operating conditions due to the difference in materials from which they are made. Cap screws 38 are threadably received in adaptor 34 and their ends are received in notches 40 in shaft sleeve 18, thus forming a driving connection between shaft sleeve 18 and adaptor 34.
Lock ring 42 encircles adaptor 34 and also flange 28, and is connected thereto (see FIG. 3 also) by elastomeric keys 44 received in transverse pockets 46 defined by flats 48 on seal ring flange 28 and grooves 50 in lock ring 42. Keys 44 provide a resilient driving connection between lock ring 42, flange 34, sleeve 18, and seal ring 20 and cushion the drive therebetween. The resilient connection also axially locates seal ring 20 and lock ring 42 during their assembly. Cap screws 38 are enclosed by ring 42. Ring 42, by enshrouding seal ring 20, prevents it from flying apart in case of its failure.
The elastomeric keys 44 exert radially inwardly directed forces on the flats 48 of the seal ring 20. When the keys 44 are subjected to torque forces, as when the frictional forces between the seal faces 24 and 26 increase, the keys exert increased forces on the ring 20 and cause the face 24 to distort and deflect in a wavy pattern, permitting increased fluid flow across the faces 24, 26 with a reduction of the friction therebetween. As torque increases, deflection of the seal faces 24 increases, so that the seal is self-compensating.
Seal ring 22 has a rearwardly extending reduced inner diameter flange 52 partially encircling balance sleeve means 54. Seal ring 22 is centered on sleeve means 54 by O-ring 56 positioned between ring 22 and sleeve 54. O-ring 56 permits limited axial movement of ring 22 relative to sleeve 54. This arrangement also avoids undesirable effects of different radial deflections of ring 22 and sleeve 54 from operating conditions due to differences in their materials of construction. The outer circumference of seal ring 22 is encircled and sealed to retainer 58 by O-rings 59 and 60. Retainer 58 also has radially inwardly directed flange 61 extending over a portion of the front of seal ring 22. Retainer 58 substantially eliminates severe radial deflections of seal ring 22 which could be caused by extreme pressure differentials in the inside and outside of ring 22. The rear of retainer 58 has a radially outwardly extending flange 64 with notches or slots 66 therethrough. Cap screws 68 with surrounding keys 70 are slidably received in notches 66, the cap screws being also received in threaded openings 72 in seal flange 14, thus connecting seal ring 22 to flange 14 and preventing rotation of seal ring 22 relative to flange 14. Keys 70 are flanged at their outer ends to limit axial movement of seal ring 22 and retainer 58 during their assembly with seal flange 14.
Retainer 58, and thus seal ring 22, are resiliently urged toward the right, as in FIG. 1 by a plurality of usually identical coil springs 74, each received in a pocket 76 in spring retainer 78 (see also FIG. 2). Spring retainer 78 is positioned in annular cavity 80 in flange 14 and has a radial front surface and a radial back surface. Some pockets 76 open to the front surface while the others open to the rear surface. These springs 74 which extend froward to the front surface of retainer 78 define a first spring set. These springs 74 which extend rearward to the rear surface of retainer 78 define a secong spring set. By such construction, the ends of those springs defining the first spring set engage surfaces which are axially spaced from the surfaces engaged by the ends of those springs defining the second spring set. The total spring force from the first and second set of springs 74 is applied to annular flange member 82 connected to retainer 58 by cap screws 84. This arrangement of springs 74 provides a substantially uniform spring load on the ring 22 under all operating conditions and permits twice the axial movement of the pump shaft compared to a more conventional spring arrangement wherein the springs are all facing in one direction. An O-ring 86 is positioned between balance sleeve means 54 and flange 14. Cap screw 88 threadably received in flange 14 and in enlarged slot 90 in sleeve 54 axially and radially positions sleeve 54 with respect to flange 14. O-ring 86 provides a hydraulic seal between sleeve means 54 and flange 14. Because sleeve means 54 is spaced from sleeve 18 and thus also from shaft 12, shaft wobble or misalignment will not affect the alignments of stationary seal ring 22 and its associated parts.
Seal ring 20 is preferably made of carbon and seal ring 22 is preferably made of a harder material, such as titanium carbide, silicon carbide, and the like. The remainder of the assembly, except for the elastomeric O-rings and keys 44, is generally made of suitable metal, depending upon the environment in which the assembly is to be used.
FIGS. 4A and 4B when laid end-to-end illustrate a multiple stage mechanical seal assembly identified as 100, each stage comprising individual seal assemblies A, B and C. Each stage is essentially identical in construction. Differences, if any, are generally in the housing parts with which the stages are associated. Sleeve 102 is continuous and extends the length of the assembly 100. Housing 104, of multiple parts, comprises plug 106, generally cylindrical part 108 with a generally centrally located flange 110, and separate end flange 112. Flange 114 is connected to plug 106 by cap screws 116 and the function of the plug 106 is essentially the same as previously described seal flange 14. Flanges 110 and 112 also function the same as seal flange 14.
The remainder of the parts are the same in each stage as in the FIG. 1 assembly except that each stationary seal ring is provided with a radial passage 116, so as to permit any seepage of fluid into a zone between seal rings 22A, 22B, and 22C and their retainers 58A, 58B and 58C to flow to the low pressure side of the seal. This prevents any pressure build-up between seal ring 22A, 22B and 22C and retainers 58A, 58B and 58C. which could damage ring 22. Generally a passage such as 116 is not necessary in a single stage seals but may be used therein if desirable. The parts in FIGS. 4A and 4B are identified using a suffix A, B or C depending upon the stage in which they are a part and reference is made to the description of the various parts. Suffice to say the the essential features of the single stage seal assembly are incorporated in each stage of the multiple stage seal assembly.
While the invention has been discussed with reference to a particular structure, it is to be understood that the claims are intended to also cover reasonable equivalents of the disclosed structure.
|
A single or multiple stage mechanical seal assembly in which one seal ring is resiliently coupled to a rotatable shaft and the other seal ring is resiliently urged toward the first seal ring by axially-arranged identical springs received in spring pockets in a spring retainer, some pockets opening at one radial surface of the retainer and others opening at the other radial surface of the retainer. The outer surfaces of the seal rings are protected against deflection by being encircled by cylindrical members and one seal ring is resiliently coupled to its encircling cylindrical member. A balance sleeve means partly supports the axially movable seal ring and is capable of angular adjustment to compensate for shaft misalignment.
| 5
|
This is a division of application Ser. No. 551,965 filed Nov. 15, 1983 now U.S. Pat. No. 4,497,954.
TECHNICAL FIELD
This invention relates to substituted cyclopentane compounds and a synthetic process useful in the preparation of compounds of pharmaceutical interest.
BACKGROUND OF THE INVENTION
Esters of benzoic acid which are substituted on the aromatic ring by 1,1-dihydroperfluoroalkoxy substituents and exhibit anesthetic activity are described in U.S. Pat. No. 3,655,728. Amides of benzoic acid which are substituted on the aromatic ring by 1,1-dihydroperfluoroalkoxy substituents and exhibit antiarrhythmic activity are described in U.S. Pat. No. 3,719,687. U.S. Pat. Nos. 3,900,481, 4,071,524 and 4,097,481 describe antiarrhythmic agents including, inter alia, N-(piperidylmethyl)benzamides substituted by one or more 1,1-dihydroperfluoroalkoxy groups. Above-mentioned U.S. Pat. No. 3,900,481 discloses the compound 2,5-bis(2,2,2-trifluoroethoxy)-N-(2-piperidylmethyl)benzamide, a particularly useful antiarrhythmic agent also known as flecainide. An article appearing in the Journal of Medicinal Chemistry, Vol. 20, pg. 821 (1977), discloses many of the compounds described in the latter patents, and also discloses various additional compounds such as 2-(2,2,2-trifluoroethoxy)-N-(2-piperidylmethyl)benzamides in which the aromatic ring is substituted in the 5-position by a non-functional group, i.e., methyl, chloro or fluoro.
U.S. Pat. No. 4,339,587 discloses 5-hydroxy-(2,2,2-trifluoroethoxy)-N-(2-piperidylmethyl)-benzamide and synthetic intermediates useful in the synthesis thereof. The compound 5-hydroxy-(2,2,2-trifluoroethoxy)-N-(2-piperidylmethyl)benzamide is a metabolite of flecainide and is useful as an intermediate in the synthesis of flecaidide and as an antiarrhythmic agent itself.
DETAILED DESCRIPTION OF THE INVENTION
In one aspect, the present invention relates to compounds of Formula I ##STR1## wherein R is selected from the group consisting of ##STR2## --CH 2 NH 2 , ##STR3##
In another aspect, the present invention relates to compounds of Formula II ##STR4## wherein A is selected from --CH 2 CF 3 and --CH 2 O; and Q is selected from ##STR5## With the proviso that A is --CH 2 CF 3 when Q is ##STR6## and A is --CH 2 CF 3 or --CH 2 O when Q is ##STR7##
The compounds of Formulas I and II are useful as synthetic intermediates in the preparation of 5-hydroxy-N-(6-oxo-2-piperidylmethyl)-2-(2,2,2-trifluoroethoxy)benzamide (a metabolite of flecainide) and 2,5-bis(2,2,2-trifluoroethoxy)-N-(6-oxo-2-piperidylmethyl)benzamide.
In still another aspect, the present invention relates to a process for preparing 5-hydroxy-N-(6-oxo-2-piperidylmethyl)-2-(2,2,2-trifluoroethoxy)benzamide and 2,5-bis(2,2,2-trifluoroethoxy)-N-(6-oxo-2-piperidylmethyl)benzamide using the above intermediates.
Synthetic 5-hydroxy-N-(6-oxo-2-piperidylmethyl)-2-(2,2,2-trifluoroethoxy)benzamide is useful as a standard for monitoring the metabolism of flecainide in mammals. As for 2,5-bis(2,2,2-trifluoroethoxy)-N-(6-oxo-2-piperidylmethyl)benzamide, it is believed that this compound could be reduced to provide flecainide and that it therefore is a useful synthetic intermediate.
The following reaction scheme, wherein B is benzyl or --CH 2 CF 3 , and B' is hydrogen (if B is benzyl) or --CH 2 CF 3 (if B is --CH 2 CF 3 ), illustrates a synthetic route by which the compounds of Formulas I and II may be obtained and the manner in which they may be used: ##STR8## In step (1), known 2-oxocyclopentanecarboxylic acid ethylene ketal (Formula III) is converted to 2-oxocyclopentanecarboxamide ethylene ketal (Formula IV) under anhydrous conditions using a conventional mixed anhydride method. More particularly, the reactant is dissolved in a suitable inert solvent such as chloroform in the presence of an organic acid acceptor such as an organic amine (e.g., triethylamine) or an inorganic acid acceptor such as sodium carbonate or sodium bicarbonate. Ethyl chloroformate or an equivalent reactive blocking agent is added to the mixture, followed by addition of anhydrous ammonia to provide the amide of Formula IV.
Alternatively, a simple lower alkyl ester of the compound of Formula III may be reacted with alcoholic ammonia by heating in a bomb to provide the amide of Formula IV.
The amide of Formula IV is readily reduced in step (2) using a metal hydride reducing agent such as lithium aluminum hydride to provide (2-oxocyclopentane)methylamine ethylene ketal (Formula V) which may be readily converted to the amine salt by conventional methods.
In step (3) the amine of Formula V is reacted with a known compound of Formula IV by heating in an inert solvent in the presence of an organic or inorganic acid acceptor such as those described above in connection with step (1). The product of step (3) is a compound of Formula VII.
In step (4) the compound of Formula VII is converted by hydrolysis to the corresponding ketone of Formula VIII by heating in an aqueous alcohol such as aqueous ethanol in the presence of dilute strong acid such as hydrochloric acid.
In step (5) the compound of Formula VIII is reacted in a conventional Schmidt-type reaction by reacting with hydrazoic acid in the presence of sulfuric acid in an inert solvent or solvent blend such as a chloroform and benzene mixture. Under these reaction conditions, if B of the compound of Formula VIII is benzyl, B' is hydrogen in the product of Formula IX. If B of the compound of Formula VIII is 2,2,2-trifluoroethyl, B' remains trifluoroethyl.
The following examples illustrate the preparation of the compounds of the invention. All temperatures in the examples are given in degrees Centigrade.
EXAMPLE 1
Preparation of the Compound of Formula IV
To a solution of about 65 g of ammonia in 200 ml of methanol was added 20 g (0.10 mole) of ethyl 2-oxocyclopentanecarboxylate ethylene ketal. The mixture was heated at 130° C. while shaking in a bomb for about 16 hours. The mixture was then filtered and the solid residue dicarded. The filtrate was evaporated, the resulting residue triturated with hexane, and the solid separated by filtration. The solid was dissolved in chloroform and passed through a chromatography column of florisil to provide 3.5 g of white solid after removal of solvent. This solid was recrystallized from toluene to provide the white needles of 2-oxocyclopentanecarboxamide ethylene ketal, m.p. 134°-136° C.
Analysis: Calculated for C 8 H 13 NO 3 : %C, 56.1; %H, 7.65; %N,8.2; Found: %C, 56.2; %H, 7.6; %N, 8.2.
EXAMPLE 2
Alternative Preparation of the Compound of Formula IV
To a stirred, cold (0° C.) solution of 1.72 g (0.01 mole) of 2-oxocyclopentanecarboxylic acid ethylene ketal in 35 ml of chloroform was added first 1.11 g (0.011 mole) of triethylamine and then 1.085 g (0.01 mole) of ethyl chloroformate, the latter being added in dropwise fashion. After stirring for 30 minutes, dry ammonia gas was bubbled in over about 5 minutes. A white solid separated while the mixture was stirred at about 0° C. for 30 minutes. The solid was separated by filtration and washed with chloroform, and the combined washings and filtrate were evaporated to provide a white solid residue of 2-oxocyclopentanecarboxamide ethylene ketal. Infrared spectral analysis showed the product to be identical to that obtained in Example 1.
EXAMPLE 3
Preparation of the Compound of Formula V
To a stirred suspension of 8.11 g (0.218 mole) of lithium aluminum hydride in 50 ml of diethyl ether under nitrogen was added, in small portions, 24.3 g (0.142 mole) of 2-oxocyclopentanecarboxamide ethylene ketal. The stirred mixture was heated at reflux for about one day, and the excess lithium aluminum hydride was then decomposed by adding sequentially and dropwise 8 ml of water, 12 ml of 10 percent aqueous sodium hydroxide solution, and an additional 20 ml of water. Filtration of the mixture followed by evaporation of the filtrate provided an oil. The oil was distilled to provide a clear, colorless liquid, b.p. 62°-65° C./0.4 mm of Hg, this being (2-oxocyclopentane)methylamine ethylene ketal.
To a solution of 0.5 g of the ketal in 50 ml of diethyl ether was added diethyl ether which had previously been saturated with hydrogen chloride until the mixture was acid to litmus paper. The solid was separated by filtration, washed with ether and recrystallized from acetonitrile to provide white solid (2-oxocyclopentane)methylamine ethylene ketal hydrochloride, m.p. 144°-146° C.
Analysis: Calculated for C 8 H 15 NO 2 .HCl: %C, 49.6; %H, 8.3; %N, 7.2; Found: %C, 49.4; %H, 8.4; %N, 7.1.
EXAMPLE 4
Preparation of the Compound of Formula VII
To a stirred suspension of 8.7 g (0.055 mole) of (2-oxocyclopentane)methylamine ethylene ketal, 17.6 g (0.166 mole) of sodium carbonate and 200 ml of benzene was added dropwise a solution of 19.1 g (0.0553 mole) of 5-benzyloxy-2-(2,2,2-trifluoroethoxy)benzoyl chloride in 100 ml of benzene. The mixture was then heated to reflux and maintained at reflux for one hour. The mixture was evaporated, and water and diethyl ether were added to the residue. The layers were separated, and the organic layer was washed with saturated sodium chloride solution and dried over magnesium sulfate. The organic layer was evaporated to provide an off-white residue. Recrystallization of a sample of the solid residue from 2:1 heptane:benzene with treatment with decolorizing charcoal provided 5-benzyloxy-N-[(2-oxocyclopentane)methyl ethylene ketal]-2-(2,2,2-trifluoroethoxy)benzamide, m.p. 81.5°-82.5° C.
Analysis: Calculated for C 24 H 36 F 3 NO 5 : %C, 61.9; %H, 5.6; %N, 3.0; Found: %C, 61.9; %H, 5.6; %N, 2.8.
EXAMPLE 5
Preparation of the Compound of Formula VIII
To a solution of 24.3 g (0.0522 mole) of 5-benzyloxy-N-[(2-oxocyclopentane)methyl ethylene ketal]-2-(2,2,2-trifluoroethoxy)benzamide in 300 ml of ethanol was added 4 ml of 3N hydrochloric acid and 300 ml of water. The mixture was gradually heated to its reflux temperature and maintained at reflux for one hour. This mixture was cooled, 100 ml of water was added thereto, and the mixture was cooled with an ice bath. The white solid was separated by filtration and washed with cold water. A sample was recrystallized from 1:1 heptane-toluene to provide 5-benzyloxy-N-(2-oxocyclopentane)methyl-2-(2,2,2-trifluoroethoxy)benzamide, m.p. 105°-107° C.
Analysis: Calculated for C 22 H 22 F 3 NO 4 : %C, 62.7; %H, 5.3; %N, 3.3; Found: %C, 62.7; %H, 5.3; %N, 3.1.
EXAMPLE 6
Preparation of the Compound of Formula IX
To a stirred, chilled (0° C.) solution of 10 ml of concentrated sulfuric acid in 120 ml of chloroform was added dropwise a solution of 15.5 g (0.0368 mole) of 5-benzyloxy-N-(2-oxocyclopentane)methyl-2-(2,2,2-trifluoroethoxy)benzamide in 40 ml of chloroform and 28 ml of a 4 molar stock solution of hydrazoic acid in toluene. Stirring was continued for 1.5 hours at 0° C. after the completion of the addition. Water (100 ml) was added to the solution, and the organic layer was separated and dried over magnesium sulfate, and then evaporated. The residue was triturated with hot toluene, and cooled. The solid was separated by filtration, recrystallized from ethyl acetate with treatment with decolorizing charcoal and cooled to provide 5-hydroxy-N-(6-oxo-2-piperidylmethyl)-2-(2,2,2-trifluoroethoxy)benzamide, m.p. 156°-158° C.
Analysis: Calculated for C 15 H 17 F 3 N 2 O 4 : %C, 52.0; %H, 4.95; %N, 8.1; Found; %C, 51.5; %H, 5.1; %N, 7.7. The structural assignment was confirmed by comparison of infrared and nuclear magnetic resonance spectra to those of the same compound prepared by an alternative synthetic procedure which is described in copending application U.S. Ser. No. 773,203 filed of even date and commonly assigned.
|
Certain substituted cyclopentanone ethylene ketal compounds, and ketones and amides derived therefrom are useful synthetic intermediates for compounds of pharmaceutical interest. A synthetic process for using the intermediates is also described.
| 2
|
FIELD OF THE INVENTION
This invention relates to systems for lining sewers, tunnels and the like, for restoring sewer or tunnel systems, the original structure of which has degraded over time. The invention particularly concerns a method of manufacturing lining sections.
BACKGROUND OF THE INVENTION
In the particular example of sewers, the sewer gas hydrogen sulphide reacts to form sulphuric acid, which attacks the mortar within the brickwork of existing sewers. Various lining systems are known, in which a lining is provided within the existing sewer or tunnel system and in which a grout, for example concrete, is introduced into the spacing between the new liner and the original structure.
The resulting sewer or tunnel wall, which comprises the original decaying structure, the grout material and the lining, is subjected to a different distribution of stresses to the original structure. In particular, this change in the stress distribution can result in a large reduction or elimination of the tensile stress in the original wall, which tensile stress typically leads to cracking and crumbling of the original wall, particularly in cases where the mortar of a brickwork structure has been under chemical attack. The level of compressive stresses in the original structure will also be reduced by the introduction of the lining system. The lining also acts as a barrier to prevent further chemical decay of the original structure.
A lining system typically comprises a number of lining sections butted end-to-end in order to form the lining for a sewer system. Each lining section may be a single closed loop or, it may comprise a number of arcuate portions connected together by appropriate joints to form the loop.
This invention is concerned in particular with the manufacture of a lining system in which the material of the lining comprises a sandwich structure having an inner and an outer fibreglass-resin layer, and a sand-resin layer sandwiched between them. A known manufacturing process for the lining is essentially manual, and involves depositing a fibreglass layer of specified thickness over a mould, applying a resin to the fibreglass layer, applying a sand-resin mixture over the fibreglass-resin layer to a desired thickness, depositing a second fibreglass layer of specified thickness over the sand-resin layer, and applying a resin to the second fibreglass layer.
A particular problem encountered in the manufacture of this sandwich structure lies in the control of the thickness of the sand-resin layer. A minimum thickness is specified for the structural properties of the lining. Conventionally, the thickness has been controlled to meet this minimum by using depth gauges, which leave visual tell-tale marks on the surface of the sand resin layer when the desired thickness has been reached or passed. This process is prone to wastage of the sand-resin composition, because the resulting sand-resin layer is thicker than required over most of the area of the structure.
An alternative method of ensuring the desired minimum thickness is obtained involves the use of a tamping device. This is a device which compresses (or displaces) the surface of the sand-resin material using a reciprocating pad, to reach a desired thickness. The sand-resin mixture is intentionally tacky, and indeed it needs to be able to grip to the surface of the underlying fibreglass-resin layer, even against the action of gravity. A problem with this method is that the sand-resin layer can adhere to the tamping pad, and thus become dislodged. Also, due to the essentially incompressible nature of the sand-resin mixture, the tamping process can only achieve the desired thickness for a limited range of depths and only if there is approximately the correct amount of sand-resin mixture to start with.
SUMMARY OF THE INVENTION
According to a first aspect of the invention, there is provided a method of manufacturing a sewer or tunnel lining section, comprising:
forming a fibreglass-resin layer over a mould;
applying a sand-resin mixture over the fibreglass-resin layer to a thickness which results in the combined structure having a thickness greater than a preset minimum thickness;
removing sand-resin material from the surface of the sand-resin layer using a wire arranged to lie a predetermined radial distance from the surface of the mould, the wire being passed around the surface of the sand-resin layer whilst maintaining the predetermined radial distance, the predetermined radial distance comprising, or being slightly greater than, the preset minimum thickness; and
forming a second fibreglass-resin layer over the sand-resin layer.
The use of a wire to remove excess sand-resin material has been found to be particularly effective, and surprisingly the excess material does not re-adhere to the underlying surface after the wire has passed. This is despite the required tackiness of the sand-resin mixture.
The first and second fibreglass-resin layers are preferably formed by depositing sheets of fibreglass material and subsequently applying the resin or by spraying particles of fibreglass material to a specified thickness and subsequently applying the resin. Preferably, the mould has a central region where the lining section is formed and side regions which provide guide surfaces, and wherein the wire is arranged to extend between a pair of roller arrangements, the wire being mounted so as to lie a predetermined distance above a surface when the roller arrangements are passed over the guide surfaces.
Each roller arrangement may comprise a single roller, with the wire extending between the two rollers along the axis of rotation of the two rollers or each roller arrangement may comprise two rollers side by side having parallel axes of rotation, the wire being positioned between the two rollers and extending parallel to the axes of rotation of the two rollers between the two roller arrangements.
The invention also provides a method of lining a sewer or tunnel, comprising inserting lining sections of the invention into the sewer or tunnel to form a lining and filling the space between the lining and the wall of the sewer or tunnel with grouting.
According to a second aspect of the invention, there is provided a device for controlling the thickness of a sand-resin mixture in a sewer or tunnel lining section, comprising
a wire extending between two roller arrangements, the wire being mounted so as to lie a predetermined distance above a surface when the roller arrangements are passed over the surface.
Each roller arrangement may comprise a single roller, the wire extending between the two rollers along the axis of rotation of the two rollers, or they may each comprise two rollers side by side having parallel axes of rotation, the wire being positioned between the two rollers and extending parallel to the axes of rotation of the two rollers between the two roller arrangements.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described by way of example, with reference to and as shown in the accompanying drawings in which:
FIG. 1 shows schematically an existing sewer system which has been lined using a lining system manufactured according to the invention;
FIG. 2 shows the structure of the lining material;
FIG. 3 shows the mould used in the method of the invention;
FIG. 4 shows a first example of device of the invention for controlling thickness; and
FIG. 5 shows a second example of device for controlling thickness.
DETAILED DESCRIPTION
FIG. 1 shows an existing sewer or other tunnel system 10 in which the wall 12 defining the channel requires repair. For this purpose, a lining 14 is introduced having a cross section which is selected depending upon the shape of the existing passageways. One possible lining structure comprises three sheets as shown in FIG. 1, a base sheet 14 a and two side sheets 14 b , 14 c . The three sheets are coupled together by tongue and groove joints 16 to form the closed loop 18 . Alternatively, the closed loop 18 may be defined by a single component. A grout material 22 is introduced between the existing wall 12 and the new lining 14 .
One preferred structure of the main body 18 of the lining is described with reference to FIG. 2 . The innermost surface of the lining is defined by a glass reinforced plastics layer 40 which provides the main structure of the lining. The plastic layer 40 is formed by applying a thermosetting resin onto a glass fibre mesh, or glass fibre particles which are obtained by passing the mesh (roving) through a chopping gun. The thermosetting resin is of the isophthalic type, for example neopentylglycol. The glass fibre material may comprise corrosion resistant glass, for example having no borosilicone. The glass fibre sheets used to form the layer 40 may comprise a lower surface tissue, which gives rise to a resin rich surface during curing, which provides a chemical barrier for the remainder of the layer 40 .
A layer 42 comprising a sand and resin mixture is provided over the plastic layer 40 to give the overall structure the desired thickness. The desired thickness will be a function of the intended stress profile to be obtained when the lining is combined with the grout material 22 and the wall of the original structure. On top of the sand/resin layer 42 is provided a further glass reinforced plastic layer 44 and a layer of aggregate 46 which defines the outer surface of the lining. This aggregate layer 46 provides a key for the grout material to be inserted between the lining and the original structure.
The grout material 22 , shown in FIG. 1, comprises a concrete mix, which may be introduced by pumping or spraying.
The method of manufacturing the lining structure described with reference to FIG. 2 will now be explained. A substantially cylindrical mould is provided, as shown in FIG. 3, and is used to produce predetermined lengths of the lining. The outer surface of the substantially cylindrical body 50 of the mould corresponds to the shape of the inner surface of the lining section. Stops 52 are provided which define the width of the section to be manufactured. These stops 52 may define flat end faces of the lining sections, as shown in FIG. 3, or else they may define interlocking shapes, such as tongue and groove joints. The lining sections may then be connected together by these lengthwise tongue and groove joints. The mould has a central region between the two stops 52 where the lining section is formed, and has side regions 54 outside of the stops 52 which provide guide surfaces.
To manufacture the structure of FIG. 2, a fibreglass-resin layer is formed over the central region of the mould. This is achieved by depositing the fibreglass layer and subsequently impregnating it with suitable resin. The fibreglass layer may be laid down as sheets with a specified thickness, or else smaller particles of fibreglass material may be sprayed on to the surface.
The sand-resin mixture is then deposited over the fibreglass-resin layer. This sand-resin matrix may, for example, comprise one part polyester resin to four parts sand, and there may additionally be provided a chalk-based binder. This mixture is applied manually, for example using a trowel to a desired thickness. The sand-resin layer must exceed a pre-set minimum thickness which is derived from the structural and physical properties of the lining section. The sand-resin layer 42 is significantly thicker than the fibreglass-resin layer 40 . For example, the layer 40 may have a thickness of 5 mm, whereas the layer 42 may have a thickness of 25 mm. The thickness of the sand-resin layer can therefore be controlled by ensuring that the total combined thickness reaches a pre-set minimum.
According to the invention, the sand-resin layer is applied to a thickness which results in the two layers 40 , 42 having a thickness greater than the pre-set minimum, and sand-resin material is then removed using a wire arrangement. This wire arrangement is located using the guide surfaces 54 , and the interaction of the wire arrangement with the guide surfaces 54 is such that the wire is suspended at the pre-set minimum thickness radially above the surface of the mould. By “radial” is meant a distance above the surface of the mould in a direction perpendicular to the tangent to the surface of the mould. The wire is passed around the surface of the sand-resin layer whilst maintaining this predetermined radial distance, and any sand-resin material removed can be caught for subsequent re-use.
After the fibreglass-resin layer 40 and sand-resin layer 42 have been deposited and reduced to the required thickness, a further fibreglass-resin layer 44 is then formed manually over the surface of the sand-resin layer 42 .
The wire arrangement comprises a wire which extends between a pair of roller arrangements, each of which engages with a respective guide surface 54 . As shown in FIG. 4, in a first example of wire arrangement, each roller arrangement 56 comprises a single roller 58 with the wire extending between the two rollers 58 along their axes of rotation. The wire arrangement has handles 60 with a structural supporting rod 62 extending between them. To keep the wire 64 straight, a central support 66 is shown attached to the support member 62 . Depending upon the span of the wire 64 , more or less than one central support 66 may be required.
With the arrangement shown in FIG. 4, the angle at which the device is held against the guide surfaces 54 is not critical, because the distance between the point of contact of the rollers 58 and the guide surfaces 54 and the wire 64 will always be constant, equalling the radius of the rollers 58 . This device may therefore be rolled manually around the mould to obtain the desired thickness of sand-resin mixture.
An alternative roller arrangement 56 is shown in FIG. 5 which comprises two rollers 68 side by side with their axes of rotation 70 parallel to each other. The wire 64 is positioned between the two rollers 68 and is also parallel to the axes of rotation 70 . The rollers 68 are mounted to a support structure 72 , and the wire 64 may be supported by a mounting 74 having a threaded outer surface which engages with a threaded bore 76 in the support structure 72 . In this way, the height of the wire above the surface of the mould may be adjustable.
The roller arrangement of FIG. 5 approximates the curved surface of the mould as a straight line between the points of contact of the two rollers 68 . The perpendicular distance of the wire 64 from this straight line is then constant. This approximation is more accurate for larger radii of curvature, and is also more accurate when the rollers 68 are closer together. Thus, the spacing of the rollers 68 will be selected as a function of the sharpest radius of curvature occurring in the surface of the mould. In the case of the lining shape shown in FIG. 1, the sharpest radius of curvature is at the base of the lining, and the spacing between the rollers 68 will then be selected to achieve a desired accuracy in the radial distance of the wire 64 from the surface of the mould at this part of the lining. The two roller arrangements 56 shown in FIG. 5 are connected together by a support structure similar to that shown in FIG. 4, and there may again be central supports 66 , if required.
|
During manufacture of a sewer or tunnel lining section, sand-resin material is deposited over a mould, to define a central part of the section. Sand-resin material is removed using a wire arranged to lie a predetermined radial distance from the surface of the mould. The wire is passed around the surface of the sand-resin layer whilst maintaining the predetermined radial distance, the predetermined radial distance comprising, or being slightly greater than a preset minimum thickness. The use of a wire to remove excess sand-resin material has been found to be particularly effective, and surprisingly the excess material does not re-adhere to the underlying surface after the wire has passed. This is despite the required tackiness of the sand-resin mixture.
| 5
|
RELATED APPLICATIONS
The instant application is a continuation-in-part of U.S. application Ser. No. 09/609,487 filed Jul. 5, 2000 now U.S. Pat. No. 6,491,866, (which is, in turn, a continuation-in-part of U.S. application Ser. No. 09/435,497, filed Nov. 6, 1999 now U.S. Pat. No. 6,193,929.
FIELD OF THE INVENTION
The instant invention relates generally to system designs and thermal considerations that allow the use of revolutionary new Ovonic hydrogen storage alloys as the fuel supply source for fuel cells. More specifically the instant invention relates to system designs that reduce the relative cost of releasing hydrogen from hydrogen storage alloys by combusting conventional fuels or exploiting other forms of waste heat to provide the heat of desorption for the hydrogen which ultimately powers the fuel cell. The hydrogen storage alloys used to store hydrogen in the systems of the instant invention are capable of storing on the order of 7 weight % hydrogen and are capable of absorbing at least 80% of their maximum capacity in 1.5 minutes and have a cycle life of at least 2000 cycles without loss of capacity or kinetics.
BACKGROUND OF THE INVENTION
The instant patent application describes system designs and thermal considerations for the economical use of hydrogen storage alloys, useful for a hydrogen-based economy. With the systems described herein, it is realistic to have automobiles which have a 300 mile range on a single fill-up of hydrogen, by burning hydrogen directly and recovering the waste heat to reduce the amount of additional heat require to release the stored hydrogen. The elements and interactive local environments of alloys, which are disclosed in U.S. Pat. No. 6,491,866 filed Jul. 5, 2000 (the '866 patent, hereby incorporated by reference) provide them with high storage capacity, excellent kinetics and long cycle life. An infrastructure system for such a hydrogen based economy, is the subject of U.S. Pat. No. 6,305,442, entitled “A Hydrogen-based Ecosystem” filed on Nov. 22, 1999 (the '442 patent), which is hereby incorporated by reference. This infrastructure, in turn, is made possible by hydrogen storage alloys that have surmounted the chemical, physical, electronic and catalytic barriers that have heretofore been considered insoluble. Other hydrogen storage alloys which are useful in such an infrastructure are fully described in U.S. Pat. No. 6,193,929 , entitled “High Storage Capacity Alloys Enabling a Hydrogen-based Ecosystem”, filed on Nov. 6, 1999 (“the '929 patent”), which is hereby incorporated by reference. The '929 patent relates to alloys which solve the unanswered problem of having sufficient hydrogen storage capacity with exceptionally fast kinetics to permit the safe and efficient storage of hydrogen to provide fuel for a hydrogen based economy, such as powering internal combustion engine and fuel cell vehicles. In the '929 patent the inventors for the first time disclosed the production of Mg-based alloys having both hydrogen storage capacities higher than about 6 wt. % and extraordinary kinetics. This revolutionary breakthrough was made possible by considering the materials as a system and thereby utilizing chemical modifiers and the principles of disorder and local order, pioneered by Stanford R. Ovshinsky, in such a way as to provide the necessary catalytic local environments, and at the same time designing bulk characteristics for storage and high rate charge/discharge cycling. In other words, these principles allowed for tailoring of the material by controlling the particle and grain size, topology, surface states, catalytic activity, microstructure, and total interactive environments for extraordinary storage capacity. Wherein disorder provides extra degrees of freedom so that atomic engineering can be applied, e.g. new compositions that have compositional, positional, and topological disorder. The function of a site can be altered and controlled by changing it's composition, position, and interaction with adjacent elements. This can be accomplished by using specific elements, modifying the number of sites, using the addition of chemical modifiers and adding/removing elements on an atomic scale to create atomic scale porosity.
The combination of the '442 and the '929 patents solves the twin basic barriers which have held back the ubiquitous use of hydrogen: 1) storage capacity; and 2) infrastructure. With the use of the alloys of the '929 patent, hydrogen can be shipped safely by boats, barges, trains, trucks, etc. when in solid form. The hydrogen infrastructure described in the '442 patent requires careful thermal management and efficient heat utilization throughout the entire system. The instant invention helps to make the necessary heat transfer between the subsystems of the infrastructure simple, efficient, and economical, by reducing the additional outside heat necessary to release the hydrogen without actually burning or combusting the hydrogen itself.
As the world's population expands, and its economy increases, the atmospheric concentrations of carbon dioxide are warming the earth causing climate change. The global energy system is moving steadily away from the carbon-rich fuels whose combustion produces the harmful gas. For nearly a century and a half, starting withe the industrial revolution, fuels with high amounts of carbon have progressively been replaced by those containing less. It had been predicted that this evolution will produce a carbon-free energy system by the end of the 21 st century. The instant invention is a means of combusting small amounts of hydrocarbon fuels to help use a carbon free energy source that will provide vehicles with a 300 mile range. In the near term, hydrogen will be used in fuel cells for cars, trucks and industrial plants, just as it already provides power for orbiting spacecraft. Hydrogen is already the fuel source used in batteries (such as the hydride batteries developed by Ovonic Battery Company which shuttle hydrogen back and forth to generate electricity, and have revolutionized the auto industry), and fuel cells use hydrogen to generate electricity. With the advent of high capacity, fast kinetics solid state storage materials, hydrogen now will provide a general carbon-free fuel to cover all fuel needs.
FIG. 1, taken from reliable industrial sources, is a graph demonstrating society's move toward a carbon-free environment as a function of time starting with the use of wood in the early 1800s, going simultaneously through the industrial revolution, and ending in about 2010 with the beginning of a “hydrogen” economy. In the 1800s, fuel was primarily wood in which the ratio of hydrogen to carbon was about 0.1. As society switched to the use of coal and oil, the ratio of hydrogen to carbon increased first to 1.3 and then to 2 and more recently to 4. However, the ultimate goal for society is to employ a carbon-free fuel, i.e., the most ubiquitous of elements, pure hydrogen. The problem has been that liquid or gaseous storage cant be safely and economically used. Solid state storage capacity and infrastructure will solve these problems. The inventors of the '929 and the '442 patents have made this possible by inventing a 7% storage material (7% is an un-optimized figure and will be increased along with better kinetics) with exceptional absorption/desorption kinetics, i.e. at least 80% charge in less than 2 minutes and an infrastructure to use these storage alloys. These alloys, following the principles of atomic engineering, allow for the first time, a safe, high capacity means of storing, transporting and delivering pure hydrogen. They allow for shipment of hydrogen in ordinary cargo containers without the strict regulations and restrictions of normal hydrogen transportation.
Hydrogen is the “ultimate fuel.” It is inexhaustible. Hydrogen is the most plentiful element in the universe and all matter contains hydrogen. Hydrogen can provide a clean source of energy for our planet and can be produced by various processes which split water into hydrogen and oxygen. The hydrogen can then be stored and transported in solid state form, therefore being economically and safely used.
While the world's oil reserves are depletable; the supply of hydrogen remains virtually unlimited. Hydrogen, which can be produced from coal, natural gas and other hydrocarbons, is preferably formed via electrolysis of water, more preferably using energy from the sun (see U.S. Pat. No. 4,678,679 ('679), the disclosure of which is incorporated herein by reference.) It should be noted that the triple-junction solar cells disclosed in the '679 patent are particularly suited to electrolysis of water, because their output voltage is exactly the voltage needed for the eletrolysis, and thus, no voltage modifying electronics are needed to perform the electrolysis. However, hydrogen can also be produced by the electrolysis of water using any other form of economical energy (e.g., wind, waves, geothermal, hydroelectric, nuclear, etc.) Furthermore, hydrogen, is an inherently low cost fuel. Hydrogen has the highest density of energy per unit weight of any chemical fuel and is essentially non-polluting since the main by-product of “burning” hydrogen is water. Thus, hydrogen can be a means of solving many of the world's energy related problems, such as climate change, pollution, strategic dependancy on oil, etc., as well as providing a means of helping developing nations.
While hydrogen has wide potential application as a fuel, a major drawback in its utilization, especially in mobile uses such as the powering of vehicles, has been the lack of an acceptable lightweight hydrogen storage medium. Storage of hydrogen as a compressed gas involves the use of large and heavy vessels. Additionally, large and very expensive compressors are required to store hydrogen as a compressed gas and compressed hydrogen gas is a very great explosion/fire hazzard.
Hydrogen also can be stored as a liquid. Storage as a liquid, however, presents a serious safety problem when used as a fuel for motor vehicles since hydrogen is extremely flammable. Liquid hydrogen also must be kept extremely cold, below −253 ° C., and is highly volatile if spilled. Moreover, liquid hydrogen is expensive to produce and the energy necessary for the liquefaction process is a major fraction of the energy that can be generated by burning the hydrogen. Another drawback to storage as a liquid is the costly losses of hydrogen due to evaporation, which can be very high.
For the first time, storage of hydrogen as a solid hydride, using the atomically engineered alloys of the '929 patent can provide a greater percent weight storage than storage as a compressed gas or a liquid in pressure tanks. Also, hydrogen storage in a solid hydride is safe and does not present any of the hazard problems that hydrogen stored in containers as a gas or a liquid does, because hydrogen, when stored in a solid hydride form, exists in it's lowest free energy state.
In addition to the problems associated with storage of gaseous or liquid hydrogen, there are also problems associated with the transport of hydrogen in such forms. For instance transport of liquid hydrogen will require super-insulated tanks, which will be heavy and bulky and will be susceptible to rupturing and explosion. Also, a portion of the liquid hydrogen will be required to remain in the tanks at all times to avoid heating-up and cooling down of the tank which would incur big thermal losses. As for gaseous hydrogen transportation, pressurized tankers could be used for smaller quantities of hydrogen, but these too will be susceptible to rupturing and explosion. For larger quantities, a whole new hydrogen pipeline transportation system would need to be constructed or the compressor stations, valves and gaskets of the existing pipeline systems for natural gas will have to be adapted and retrofitted to hydrogen use. This assumes, of course, that the construction material of these existing pipelines will be suited to hydrogen transportation.
A high hydrogen storage capacity per unit weight of material is an important consideration in applications where the hydride does not remain stationary. A low hydrogen storage capacity relative to the weight of the material reduces the mileage and hence the range of the vehicle making the use of such materials impractical. A low desorption temperature (in the neighborhood of 300° C.) is desirable to reduce the amount of energy required to release the hydrogen. Furthermore, a relatively low desorption temperature to release the stored hydrogen is necessary for efficient utilization of the available exhaust heat from vehicles, machinery, or other similar equipment.
Good reversibility is needed to enable the hydrogen storage material to be capable of repeated absorption-desorption cycles without significant loss of its hydrogen storage capabilities. Good kinetics are necessary to enable hydrogen to be absorbed or desorbed in a relatively short period of time. Resistance to poisons to which the material may be subjected during manufacturing and utilization is required to prevent a degradation of acceptable performance.
The prior art metallic host hydrogen storage materials include magnesium, magnesium nickel, vanadium, iron-titanium, lanthanum pentanickel and alloys of these metals others. No prior art material, however, has solved the aforementioned problem which would make it suitable for a storage medium with widespread commercial utilization which can revolutionize the propulsion industry and make hydrogen a ubiquitous fuel.
Thus, while many metal hydride systems have been proposed, the Mg systems have been heavily studied since elemental Mg can store over 7 weight % of hydrogen. While magnesium can store large amounts of hydrogen, prior to our work (using d & f orbital elemental modification, causing new bonding options with local environments), it has had the disadvantage of extremely slow kinetics. For example, magnesium hydride is theoretically capable of storing hydrogen at approximately 7.6% by weight computed using the formula: percent storage=H/H+M, where H is the weight of the hydrogen stored and M is the weight of the material to store the hydrogen (all storage percentages hereinafter referred to are computed based on this formula). Unfortunately, despite high storage capacity, prior art materials were useless because discharge of the hydrogen took days. While a 7.6% storage capacity is ideally suited for on board hydrogen storage for use in powering vehicles, it requires the instant invention to form Mg-based alloys operating on principles of disorder to alter previously unuseable materials and make them commercially acceptable for widespread use.
Magnesium is very difficult to activate. For example, U.S. Pat. No. 3,479,165 discloses that it is necessary to activate magnesium to eliminate surface barriers at temperatures of 400° C. to 425° C. and 1000 psi for several days to obtain a reasonable (90%) conversion to the hydride state. Furthermore, desorption of such hydrides typically requires heating to relatively high temperatures before hydrogen desorption begins. The aforementioned patent states that the MgH 2 material must be heated to a temperature of 277° C. before desorption initiates, and significantly higher temperatures and times are required to reach an acceptable operating output. Even then, the kinetics of pure Mg are unacceptable, i.e., unuseable. The high desorption temperature makes the prior art magnesium hydride unsuitable.
Mg-based alloys have been considered for hydrogen storage also. The two main Mg alloy crystal structures investigated have been the A 2 B and AB 2 alloy systems. In the A 2 B system, Mg 2 Ni alloys have been heavily studied because of their moderate hydrogen storage capacity, and lower heat of formation ('64 kJ/mol)than Mg. However, because Mg 2 Ni has the possibility of a storage capacity of up to 3.6 wt. % hydrogen, researchers have attempted to improve the hydrogenation properties of these alloys through mechanical alloying, mechanical grinding and elemental substitutions. However, 3.6 wt. % is not nearly high enough and the kinetics are likewise insufficient.
More recently, investigators have attempted to form MgNi 2 type alloys for use in hydrogen storage. See Tsushio et al, Hydrogenation Properties of Mg-based Laves Phase Alloys, Journal of Alloys and Compounds , 269 (1998), 219-223. Tsushi et al. determined that no hydrides of these alloys have been reported, and they did not succeed in modifying MgNi 2 alloys to form hydrogen storage materials.
Finally, the instant inventors have worked on high Mg content alloys or elementally modified Mg. For instance, in U.S. Pat. Nos. 5,976,276; 5,916,381; and 6,103,024, Sapru, et al have produced mechanically alloyed Mg—Ni—Mo and Mg—Fe—Ti materials containing about 75 to 95 atomic percent Mg, for thermal storage of hydrogen. These alloys are formed by mixing the elemental ingredients in the proper proportions in a ball mill or attritor and mechanically alloying the materials for a number of hours to provide the mechanical alloy. While these alloys have improved storage capacities as compared with Mg 2 Ni alloys, they have lower plateau pressures than are acceptable.
Another example of modified high Mg content alloy is disclosed in U.S. Pat. No. 4,431,561 ('561) to Ovshinsky et al., the disclosure of which is hereby incorporated by reference. In the '561 patent, thin films of high Mg content hydrogen storage alloys were produced by sputtering. While this work was remarkable in applying fundamental principles to drastically improve the storage capacities, it was not until the invention described herein that all necessary properties of high storage capacity, good kinetics and good cycle life were brought together.
In U.S. Pat. No. 4,623,597 (“the '597 patent”), the disclosure of which is incorporated by reference, one of the present inventors, Ovshinsky, described disordered multicomponent hydrogen storage materials for use as negative electrodes in electrochemical cells for the first time. In this patent, Ovshinsky describes how disordered materials can be tailor-made to greatly increase hydrogen storage and reversibility characteristics. Such disordered materials are formed of one or more of amorphous, microcrystalline, intermediate range order, or polycrystalline (lacking long range compositional order) wherein the polycrystalline material may include one or more of topological, compositional, translational, and positional modification and disorder, which can be designed into the material. The framework of active materials of these disordered materials consist of a host matrix of one or more elements and modifiers incorporated into this host matrix. The modifiers enhance the disorder of the resulting materials and thus create a greater number and spectrum of catalytically active sites and hydrogen storage sites.
The disordered electrode materials of the '597 patent were formed from lightweight, low cost elements by any number of techniques, which assured formation of primarily non-equilibrium metastable phases resulting in the high energy and power densities and low cost. The resulting low cost, high energy density disordered material allowed such Ovonic batteries to be utilized most advantageously as secondary batteries, but also as primary batteries and are used today worldwide under license from the assignee of the subject invention.
Tailoring of the local structural and chemical order of the materials of the '597 patent was of great importance to achieve the desired characteristics. The improved characteristics of the anodes of the '597 patent were accomplished by manipulating the local chemical order and hence the local structural order by the incorporation of selected modifier elements into a host matrix to create a desired disordered material. The disordered material had the desired electronic configurations which resulted in a large number of active sites. The nature and number of storage sites was designed independently from the catalytically active sites.
Multiorbital modifiers, for example transition elements, provided a greatly increased number of storage sites due to various bonding configurations available, thus resulting in an increase in energy density. The technique of modification especially provides non-equilibrium materials having varying degrees of disorder provided unique bonding configurations, orbital overlap and hence a spectrum of bonding sites. Due to the different degrees of orbital overlap and the disordered structure, an insignificant amount of structural rearrangement occurs during charge/discharge cycles or rest periods therebetween resulting in long cycle and shelf life.
The improved battery of the '597 patent included electrode materials having tailor-made local chemical environments which were designed to yield high electrochemical charging and discharging efficiency and high electrical charge output. The manipulation of the local chemical environment of the materials was made possible by utilization of a host matrix which could, in accordance with the '597 patent, be chemically modified with other elements to create a greatly increased density of catalytically active sites for hydrogen dissociation and also of hydrogen storage sites.
The disordered materials of the '597 patent were designed to have unusual electronic configurations, which resulted from the varying 3-dimensional interactions of constituent atoms and their various orbitals. The disorder came from compositional, positional and translational relationships of atoms. Selected elements were utilized to further modify the disorder by their interaction with these orbitals so as to create the desired local chemical environments.
The disorder described in the '597 patent can be of an atomic nature in the form of compositional or configurational disorder provided throughout the bulk of the material or in numerous regions of the material. The disorder also can be introduced into the host matrix or on the surface by creating microscopic phases within the material which mimic the compositional or configurational disorder at the atomic level by virtue of the relationship of one phase to another. For example, disordered materials can be created by introducing microscopic regions of a different kind or kinds of crystalline phases, or by introducing regions of an amorphous phase or phases, or by introducing regions of an amorphous phase or phases in addition to regions of a crystalline phase or phases. The interfaces between these various phases can provide surfaces which are rich in local chemical environments which provide numerous desirable sites for electrochemical hydrogen storage.
Certain differences between chemical and thermal hydrides are fundamental. The thermal hydride alloys of the present inventions have been designed as a distinct class of materials with their own basic problems to be solved, which problems as shown in the following Table 1 are antithetical to those to be solved for electrochemical systems.
During utilization of the hydrogen stored in these aforementioned hydrogen storage alloys, heat is required to release the hydrogen from the alloys. There are a number of ways in which this heat can be provided. For example, when the hydrogen is to be supplied to an internal combustion engine, the heat can come from the exhaust of the engine itself. However, when the hydrogen is to be supplied to a fuel cell, it is difficult to use that exhaust heat to release the stored hydrogen from the storage bed. Thus, another source of heat is needed.
While hydrogen itself can be burned or catalytically combusted to provide the necessary heat, this reduces the hydrogen available to the fuel cell, thus increasing the weight and volume of the storage bed required to supply a fixed mass of hydrogen to the fuel cell. For instance, in a typical fuel cell vehicle, some of the stored hydrogen may be needed to provide the heat necessary to release all of the stored hydrogen and heat up the surrounding components (i.e. casings, heat transfer components, etc.). Obviously it is necessary to minimize this loss of available hydrogen.
Thus, there is a strong felt need in the art for a system which provides the required heat to release the stored hydrogen without burning hydrogen. Such a system is described hereinafter.
TABLE 1
Electrochemical
Gas Phase (Thermal)
Hydrogen
Hydrogen
Storage Material
Storage Material
Mechanism
H 2 O molecule splits
H 2 dissociates at the
material surface
Environment
Alkaline oxidizing
H 2 gas - very
environment
susceptible to poisoning
(KOH electrolyte)
by oxygen (inoperative
in presence of KOH)
Kinetics
Hydrogen storage/release
Hydrogen storage
at room temperature
anywhere from 20° C.
to 100° C.
Thermodynamics
Specific range of useful
M—H bond strength of
M—H bond strength
varying degrees is
preferred
Thermal
Small effect
Large effect
Conductivity
Electrical
Large effect
Small effect
Conductivity
Chemical Reaction
M + H 2 O +
H 2 (g) 2H
e − MH + OH −
SUMMARY OF THE INVENTION
The instant invention provides system designs that reduce the relative cost of releasing hydrogen from hydrogen storage alloys by combusting conventional fuels to provide the heat of desorption. The system includes means to store the conventional fuel; a means to combust the conventional fuel, and a means to provide the heat produced by combusting the conventional fuel to the storage bed for release of the stored hydrogen.
The alloys used to store the hydrogen are high capacity, low cost, light weight thermal hydrogen storage alloy materials having fast kinetics in the form of a magnesium based hydrogen storage alloy powder. These alloys, for the first time make it feasible to use solid state storage and delivery of hydrogen to power a hydrogen based economy, and particularly to power mobile energy consumer applications such as internal combustion engine or fuel cell vehicles. The alloy contains greater than about 90 weight % magnesium and has a) a hydrogen storage capacity of at least 6 weight %; b) absorption kinetics such that the alloy powder absorbs 80% of it's total capacity within 10 minutes at 300° C.; c) a cycle life of at least 500 cycles without loss of capacity or kinetics. More preferably the alloy powder has a hydrogen storage capacity of at least 6.5 weight % and most preferably at least 6.9 weight % and yet more preferentially 7 wt %. Also, the alloy powder more preferably absorbs 80% of it's total capacity within 5 minutes at 300° C. and most preferably within 1.5 minutes. The material preferably cycles at least 650 times, more preferably at least 1000 times, and most preferentially at least 2000 times without loss of kinetics or capacity.
Modifier elements added to the magnesium to produce the alloys mainly include Ni and Mm (misch metal) and can also include additional elements such as Al, Y and Si, as well as modifier elements such as carbon and boron which are light weight, absorb hydrogen, and change the local active environment. Boron allows for the acceptance of two electrons which changes the number of available electrons for forming hybridized hydrogen storage sites. A hybridized hydrogen storage site is where hydrogen is surrounded by a few electrons, but not a normal lattice storage site. Thus the alloys will typically contain 0.5-2.5 weight % nickel and about 1.0-4.0 weight % Mm (predominantly contains Ce and La and Pr). The alloy may also contain one or more of 3-7 weight % Al, 0.1-1.5 weight % Y and 0.3-1.5 weight % silicon.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph having time plotted on the abscissa and the H/C ratio plotted on the ordinate, said graph demonstrating the movement of society toward carbon-free sources of fuel;
FIG. 2, shows a schematic representation of a hydrogen gas supply system which utilizes the alloy of the instant invention for powering an internal combustion engine vehicle;
FIG. 3, shows a schematic representation of a hydrogen gas supply system which utilizes the alloy of the instant invention for powering for a fuel cell vehicle.
FIG. 4 is an absorption plot of stored hydrogen versus time for an alloy material of the instant invention for cycles 50, 650 and 2054, specifically showing that alloy materials of the instant invention have basically the same hydrogen storage capacity and absorption kinetics at cycle 2054 as they do at cycle 50;
FIG. 5 is a plot of the absorption kinetics of the FC-86 alloy specifically plotted is weight % hydrogen desorption versus time for 3 different temperatures;
FIG. 6 is a plot of the absorption kinetics of FC-76 alloy powders having two different particle sizes;
FIG. 7 shows an embodiment of the instant invention where a support means bonded with the hydrogen storage alloy material is spirally wound into a coil; and
FIG. 8 shows an alternate embodiment of the instant invention where a support means bonded with the hydrogen storage alloy material is assembled as a plurality of stacked disks.
DETAILED DESCRIPTION OF THE INVENTION
As mentioned above, when a hydrogen storage alloy bed is used as the source of fuel for an internal combustion engine, the excess heat from the engine exhaust can be used to heat the hydrogen storage bed to release more hydrogen. FIG. 2 is a schematic diagram of such a system. The system depicts a hydrogen gas supply system for an ICE vehicle. The supply system supplies a hydrogen engine 1 with hydrogen gas. The system has a hydrogen gas storage portion 2 and an engine waste heat transfer supply passage 3 which leads engine waste heat (in the form of exhaust gas or engine coolant) discharged from the engine 1 to the hydrogen gas storage portion 2 . The system also includes a return passage 4 for returning any engine coolant used to heat the hydrogen storage material back to the engine 1 and an exhaust gas vent 7 for releasing used exhaust gas. The system further includes a hydrogen gas supply passage 5 which leads hydrogen gas from the hydrogen gas storage portion 2 to the engine 1 . The engine waste heat transfer supply passage 3 is provided with a temperature regulating portion 6 which regulates the temperature of the waste heat to be introduced into the hydrogen gas storage portion 2 . With such a system, waste heat generated within the ICE can be efficiently used to heat the hydrogen storage material to release hydrogen therefrom for use in the ICE.
As discussed above, when such a fuel supply system is used with a fuel cell, very little usable waste heat is available to release the stored hydrogen from the storage bed, and combusting hydrogen is a very uneconomical method of providing the required heat. Therefore, the instant inventors have developed the present system to economically release the stored hydrogen. FIG. 3 shows a schematic representation of a hydrogen gas supply system for a FC vehicle, which is for supplying a fuel cell 8 with hydrogen gas. The system has a hydrogen gas storage portion 12 and a transfer supply passage 9 which leads unused hydrogen discharge from the fuel cell 8 to a fuel combustor 10 . The combustor 10 combusts unused hydrogen and secondary fuel to heat a thermal transfer medium which is in turn supplied to the storage bed 12 , via supply conduit 13 , thus providing the necessary heat to release the stored hydrogen. Once the heat from the thermal transfer medium has been transferred to the hydrogen storage bed, the thermal transfer medium is returned to the combustor 10 via return conduit 14 . Hydrogen is supplied to the combustor 10 via unused hydrogen from the fuel cell 8 , and a secondary fuel, which is stored in tank 17 , is transferred to the combustor via supply conduit 18 . The system also includes an exhaust gas vent 15 for releasing used combustor gas. The system further includes a hydrogen gas supply passage 11 which leads hydrogen gas from the hydrogen gas storage unit 12 to the fuel cell 8 .
The secondary fuel may be any fuel which is readily available, inexpensive and easily stored. Examples of such a fuel are gasoline, fuel oil, propane, diesel fuel, natural gas, etc. The preferred fuel is propane, and the preferred method of storing the propane is in liquid form. The combustor 10 may be any means that utilizes the secondary fuel to produce the required heat to release the hydrogen. Examples of a combustor include flame based burners, internal combustion engines, catalytic combustors, etc. The preferred combustor is a catalytic combustor. Such a catalytic combustor may be a separate unit, or may be combined with the storage bed for more efficient use of the heat of combustion. Specifically, it is noted that merely two gallons of propane would be needed to release all the stored hydrogen required to travel 300 miles with a typical hydrogen powered fuel cell vehicle. This makes the vehicle a very low emission vehicle.
While the specific description of the present system includes a secondary fuel and a means for combustion of the secondary fuel to generate heat to release the stored hydrogen from it's storage bed, other sources of available waste heat can be used, individually or in combination with the secondary fuel. Other sources can include 1) energy from batteries coupled with electrical heating elements, 2) heated waste water from the fuel cell which is converted to steam, and 3) heat/energy released from braking of the vehicle (such as from the brake linings or regenerative braking).
Alloys which are useful for the storage beds of the instant invention contain greater than about 90 weight % magnesium, and contain at least one modifier element. The at least one modifier element creates a magnesium based alloy which have a cycle life of at least 650 cycles without loss of either kinetics or storage capacity. More preferably the materials have a cycle life of at least 1000 cycles and most preferably they have a cycle life of at least 2000 cycles. The alloys are capable of storing at least 6 weight % hydrogen. More preferably the modified alloys are capable of storing at least 6.5 weight % hydrogen and most preferably the modified alloy stores at least 7 weight % hydrogen. The alloys are also capable of absorbing at least 80% of the full storage capacity of hydrogen in under 10 minutes at 300° C., more preferably within under 5 minutes and most preferably in under 1.5 minutes. The modifier elements mainly include Ni and Mm (misch metal) and can also include additional elements such as Al, Y and Si, as well as modifier elements such as carbon and boron which are light weight, absorb hydrogen, and change the local active environment. Boron allows for the acceptance of two electrons which changes the number of available electrons for forming hybridized hydrogen storage sites. A hybridized hydrogen storage site is where hydrogen is surrounded by a few electrons, but not a normal lattice storage site. Thus the alloys will typically contain 0.5-2.5 weight % nickel and about 1.0-4.0 weight % Mm (predominantly contains Ce and La and Pr). The alloy may also contain one or more of 3-7 weight % Al, 0.1-1.5 weight % Y and 0.3-1.5 weight % silicon.
EXAMPLE
A modified Mg alloy having the designation FC-86 was made which has a composition: 95 wt. % Mg, 2 wt. % Ni and 3.0 wt % Mm. The individual raw alloying elements were mixed in a glove box. The mixture was placed in a graphite crucible and the crucible was placed in a furnace. The crucible had a 2.0 mm boron nitride orifice at the bottom thereof which is plugged by a removable boron nitride rod. The furnace was pumped down to very low pressure and purged three times with argon. The argon pressure withing the furnace was brought up to 1 psi and kept at this pressure as the crucible was heated to 750° C. Once the melt was ready, the boron nitride rod was lifted and argon was injected into the furnace under pressure. The molten alloy flowed out of the graphite crucible through the boron nitride orifice and onto a non-water-cooled, horizontally spinning, copper wheel. The wheel, which spins at about 1400 rpm, solidifies the molten alloy into particles which then bounce off a water-cooled copper cap which covers the spinning wheel, and drop into a stainless steel pan where they gradually cool. Five grams of the solidified alloy flakes were mixed with 100 mg of graphite grinding aid. The mixture was mechanically ground for 3 hours. The ground alloy was then classified by sieving to recover material having a particle size of between 30 and 65 microns. The alloy has a storage capacity of about 7 wt. % hydrogen and absorbs 80% of the maximum capacity in less than 2.3 minutes at a temperature of about 275° C. (and can adsorb 80% in less than 1.5 minutes at higher temperatures). Other details of the alloy properties are presented below.
The alloys of the instant invention are unique in their combination of high storage capacity and excellent absorption/desorption kinetics. The instant inventors have found that a combination of both alloy composition and particle size of the hydrogen storage material have a significant effect on the kinetics. That is, the instant inventors have found that the kinetics of the material (regardless of specific composition) can improve with decreasing particle size, which increases surface states. Also, including carbon particles on the surface of the material increases surface states. This can be achieved by mechanically alloying the powdered alloy materials of the instant invention with carbon materials. Thus the alloy can be made via rapid solidification, and then additional surface states can be added by mechanically grinding and/or alloying. Specifically, the instant inventors have found that materials having a particle size of between about 30 and 70 microns are the most useful. This particle size gives excellent kinetics while still being capable of being manufactured.
It is significant to note that the kinetics and capacity of the alloys of the instant invention do not degrade with cycling. This can be seen graphically in FIG. 4 which is an absorption plot of stored hydrogen versus time for an alloy material of the instant invention at 300° C. for cycle 50 (represented by the ▴ symbol), cycle 650 (represented by the symbol) and cycle 2054 (represented by the ♦ symbol). As shown in FIG. 4, the alloy materials of the instant invention have virtually identical hydrogen storage capacity and absorption kinetics at cycle 2054 as they do at cycle 50. While the present test was terminated at 2054 cycles, all factors indicate that the instant alloys can easily achieve cycle lives of at least 5000 cycles or greater without loss of capacity or kinetics.
FIG. 5 is a plot of the absorption kinetics of the FC-86 alloy. Specifically, weight % hydrogen absorption versus time is plotted for 3 temperatures 230° C. (⋄ symbol), 240° C. (∘ symbol), and 275° C. (* symbol). As can be seen, at 230° C. the alloy absorbs 80% of it's total capacity in 5.2 minutes, at 300° C. the alloy absorbs 80% of it's total capacity in 2.4 minutes, and at 325° C. the alloy absorbs 80% of it's total capacity in 2.3 minutes.
FIG. 6 is a plot of the absorption kinetics of alloy material powders of the instant invention having two different particle sizes. Specifically, weight % hydrogen absorption versus time is plotted for material having a particle size range of 75-250 microns (∘ symbol), and 32-63 microns (⋄ symbol). As can be seen, the smaller particle size greatly enhances the absorption kinetics.
While the method of forming the instant powders in the examples above was rapid solidification and subsequent grinding, gas atomization may also be used. When the materials are ground, use of an attritor is the preferred method of grinding. Particularly useful is the addition of a grinding agent, such as carbon, when grinding these alloys.
The present invention includes a metal hydride hydrogen storage means for storing hydrogen within a container or tank. In one embodiment of the present invention, the storage means comprises a the afore described hydrogen storage alloy material physically bonded to a support means. Generally, the support means can take the form of any structure that can hold the storage alloy material. Examples of support means include, but are not limited to, mesh, grid, matte; foil, foam and plate. Each may exist as either a metal or non-metal.
The support means may be formed from a variety of materials with the appropriate thermodynamic characteristics that can provide the necessary heat transfer mechanism. These include both metals and non-metals. Preferable metals include those from the group consisting of Ni, Al, Cu, Fe and mixtures or alloys thereof. Examples of support means that can be formed from metals include wire mesh, expanded metal and foamed metal.
The hydrogen storage alloy material may be physically bonded to the support means by compaction and/or sintering processes. The alloy material is first converted into a fine powder. The powder is then compacted onto the support means. The compaction process causes the powder to adhere to and become an integral part of the support means. After compaction, the support means that has been impregnated with alloy powder is preheated and then sintered. The preheating process liberates excess moisture and discourages oxidation of the alloy powder. Sintering is carried out in a high temperature, substantially inert atmosphere containing hydrogen. The temperature is sufficiently high to promote particle-to-particle bonding of the alloy material as well as the bonding of the alloy material to the support means.
The support means/alloy material can be packaged within the container/tank in many different configurations. FIG. 7 shows a configuration where the support means/alloy material is spirally wound into a coil. FIG. 8 shows an alternate configuration where the support means/alloy material is assembled in the container as a plurality of stacked disks. Other configurations are also possible (e.g. stacked plates).
Compacting and sintering alloy material onto a support means increases the packing density of the alloy material, thereby improving the thermodynamic and kinetic characteristics of the hydrogen storage system. The close contact between the support means and the alloy material improves the efficiency of the heat transfer into and out of the hydrogen storage alloy material as hydrogen is absorbed and desorbed. In addition, the uniform distribution of the support means throughout the interior of the container provides for an even temperature and heat distribution throughout the bed of alloy material. This results in a more uniform rates of hydrogen absorption and desorption throughout the entirety thereof, thus creating a more efficient energy storage system.
One problem when using just alloy powder (without a support means) in hydrogen storage beds is that of of self-compaction due to particle size reduction. That is, during repeated hydriding and dehydriding cycles, the alloy materials expand and contract as they absorb and desorb hydrogen. Some alloy materials have been found to expand and contract by as much as 25% in volume as a result of hydrogen introduction into and release from the material lattice. As a result of the dimensional change in the alloy materials, they crack, undergo fracturing and break up into finer and finer particles. After repeated cycling, the fine particles self-compact causing inefficient hydrogen transfer as well as high stresses that are directed against the walls of the storage container.
However, the processes used to attach the alloy material onto the support means keeps the alloy particles firmly bonded to each other as well as to the support means during the absorption and desorption cycling. Furthermore, the tight packaging of the support means within the container serves as a mechanical support that keeps the alloy particles in place during the expansion, contraction and fracturing of the material.
While the invention has been described in connection with preferred embodiments and procedures, it is to be understood that it is not intended to limit the invention to the described embodiments and procedures. On the contrary it is intended to cover all alternatives, modifications and equivalence which may be included within the spirit and scope of the invention as defined by the claims appended hereinafter.
|
Hydrogen propelled fuel cell vehicle system designs that reduce the relative cost of releasing hydrogen from hydrogen storage alloys by providing and/or utilizing secondary sources of heat to supply the heat of desorption of stored hydrogen. The secondary source can include combusting conventional secondary (non-hydrogen) fuels. The fuel supply system uses fundamentally new magnesium-based hydrogen storage alloy materials which for the first time make it feasible and practical to use solid state storage and delivery of hydrogen to power fuel cell vehicles. These exceptional alloys have remarkable hydrogen storage capacity of over 7 weight % coupled with extraordinary absorption kinetics such that the alloy powder absorbs 80% of its total capacity within 1.5 minutes at 300° C. and a cycle life of at least 2000 cycles without loss of capacity or kinetics.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application relates to and claims priority from Japanese Patent Application No. 2008-022675, filed on Feb. 1, 2008, the entire disclosure of which is incorporated herein by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The present invention relates to a biological sample reaction chip and to a biological sample reaction method for carrying out biological sample reactions such as nucleic acid amplification.
[0004] 2. Related Art
[0005] Growing attention is being focused on methods for carrying out, for instance, chemical analysis, chemical synthesis or bio-related analysis using microfluidic chips in which microchannels are provided in a glass plate or the like. Microfluidic chips, which are also called micro-Total Analytical Systems (micro-TAS), Lab-on-a-chip and the like, are advantageous in that they require smaller amounts of specimens and reagents, have shorter reaction times and generate fewer waste products than existing devices. Thus, microfluidic chips are thus a promising application in a wide range of fields such as medical diagnosis, environmental and foodstuff onsite analysis, and in the manufacture of pharmaceuticals and chemicals, where test costs can be reduced since reaction amounts may be small. Likewise, testing can be made more efficient by considerably shortening also reaction times, since samples and reagents are used in small amounts. When used in medical diagnosis, in particular, microfluidic chips are advantageous in that they can use less of a specimen, for instance a blood sample, which allows easing the burden placed on the patient.
[0006] Known methods for amplifying genes such as DNA and RNA, used as samples, include polymerase chain reaction (PCR). In PCR, a mixture of target DNA and reagents is placed in a tube where the reagents and the target DNA are made to react, by repeating a so-called thermal cycle that involves changes of temperature in three stages, for instance, 55° C., 72° C. and 94° C., over several minutes, using a temperature control device. In each temperature cycle the target DNA can be amplified, to roughly a double amount, through the action of an enzyme called polymerase.
[0007] So-called real-time PCR, using special fluorescent probes, has come into use in recent years. In real-time PCR, DNA can be quantified while the amplification reaction is taking place. Real-time PCR boasts high measurement sensitivity and reliability, and is hence widely used in research and clinical testing.
[0008] Conventional devices, however, were problematic in that the amount of reaction liquid required for PCR is normally of several tens of μl, while basically only one gene could be determined in one reaction system. Some methods allow measuring simultaneously about four genes by introducing plural fluorescent probes and discriminating between respective colors, but determining simultaneously more than four genes inevitably calls for an increase in the number of reaction systems. The amount of DNA extracted from the specimen is normally small, and reagents are expensive. It has been thus difficult to determine simultaneously multiple reaction systems.
[0009] JP-A-2006-126010 and JP-A-2006-126011 disclose inventions in which liquid analyte samples such as a PCR reaction solution or blood are accurately introduced into a plurality of chambers, using a rotationally driven device.
[0010] JP-A-2000-236876 discloses a method that involves preparing micro-wells integrated on a semiconductor substrate, and carrying out PCR in the wells, to amplify and analyze collectively multiple DNA samples, using small sample amounts.
SUMMARY
[0011] An advantage of some aspects of the invention is to provide a biological sample reaction chip and a biological sample reaction method that allow a reaction to be carried out with a small amount of reaction liquid and that allow processing efficiently multiple specimens at a time.
[0012] A biological sample reaction chip according to an aspect of the invention includes: a plurality of reaction containers; a reaction liquid introduction channel having a reaction liquid supply opening at a first end and an evacuation opening at a second end; and a reaction liquid quantifying channel, a third end of which is connected to one of the reaction containers, and a fourth end of which is connected to the reaction liquid introduction channel, such that an interior of each of the reaction containers is coated with a reagent that is necessary for a reaction.
[0013] In this case, a reaction liquid is fed from the reaction liquid introduction channel into the reaction containers via the reaction liquid quantifying channels. Reactions using extremely small amounts of reaction liquid are made possible thereby, something that is difficult to achieve by pipette quantifying. The cost of reagents and so forth can be reduced when using small amounts reaction liquid. Also, reaction times are shortened considerably, which enhances processes efficiency. Moreover, reactions can take place in multiple reaction containers at a time, which allows conducting multiple tests and the like with good efficiency.
[0014] The reaction liquid is introduced into the reaction containers after having resided in the reaction liquid quantifying channels, whereby contamination between reaction containers can be prevented.
[0015] Reagents necessary for the reactions are coated on each reaction container, and hence the user can easily conduct tests and the like simply by filling reaction liquid.
[0016] A volume of the reaction containers may be smaller than A volume of the reaction liquid quantifying channels.
[0017] A biological sample reaction method according to an aspect of the invention is a biological sample reaction method using the above-mentioned biological sample reaction chip, the method including: reducing the pressure inside the reaction containers, the reaction liquid quantifying channels and the reaction liquid introduction channel to a predetermined pressure; filling a reaction liquid into the reaction liquid introduction channel via the reaction liquid supply opening; introducing the reaction liquid into the reaction liquid quantifying channels by reverting the pressure inside the reaction containers, the reaction liquid quantifying channels and the reaction liquid introduction channel to a pressure outside the chip; removing the reaction liquid from the reaction liquid introduction channel; introducing into the reaction containers the reaction liquid in the reaction liquid quantifying channels, by centrifugal force; and carrying out a biological sample reaction process.
[0018] In this case, a reaction liquid is fed from the reaction liquid introduction channel into the reaction containers via the reaction liquid quantifying channels. Reactions using extremely small amounts of reaction liquid are made possible thereby, something that is difficult to achieve by pipette quantifying. The cost of reagents and so forth can be reduced when using small amounts reaction liquid. Also, reaction times are shortened considerably, which enhances processes efficiency. Moreover, reactions can take place in multiple reaction containers at a time, which allows conducting multiple tests and the like with good efficiency.
[0019] The reaction liquid is introduced into the reaction containers after having resided in the reaction liquid quantifying channels, whereby contamination between reaction containers can be prevented.
[0020] In the reduction of the pressure to the predetermined pressure, the pressure is preferably reduced to a pressure ranging from 50% of the pressure outside the chip to less than the pressure outside the chip.
[0021] That way, the reaction liquid is prevented from reaching the reaction containers during introduction of the reaction liquid into the reaction liquid quantifying channels. Also prevented is contamination across neighboring reaction containers, via the reaction liquid quantifying channels and the reaction liquid introduction channel, which occurs when certain reagents applied beforehand on the reaction containers leach out into the reaction liquid.
[0022] The biological sample reaction process may be a process including nucleic acid amplification, the reaction liquid may have a target nucleic acid, an enzyme for amplifying nucleic acid and nucleotides, at predetermined concentrations, and the reaction containers may be coated beforehand with primers.
[0023] When carrying out real-time PCR, fluorescent probes may be applied beforehand in the reaction apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1A is a top-side view diagram illustrating the schematic constitution of a microreactor array according to Embodiment 1 of an aspect of the invention;
[0025] FIG. 1B is a cross-sectional diagram of FIG. 1A along line C-C;
[0026] FIG. 2 is a schematic diagram illustrating an example of a device for reducing pressure inside the microreactor array;
[0027] FIG. 3 is a schematic diagram illustrating another method of reducing pressure inside the microreactor array;
[0028] FIG. 4A , FIG. 4B , FIG. 4C , and FIG. 4D are schematic diagrams for explaining a method of filling a reaction liquid into the microreactor array; and
[0029] FIG. 5 is a diagram illustrating the schematic constitution of a centrifugation device that imparts centrifugal force on the microreactor array.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0030] An embodiment of an aspect of the invention is explained below with reference to accompanying drawings. Embodiment 1
[0031] FIG. 1A is a top-side view diagram illustrating the schematic constitution of a microreactor array (biological sample reaction chips) 10 according to Embodiment 1 of an aspect of the invention, and FIG. 1B is a cross-sectional diagram of FIG. 1A along line C-C. As illustrated in the figure, the microreactor array 10 has a transparent plate (first plate) 101 , a transparent plate (second plate) 102 , reaction container 103 , reaction liquid quantifying channels 104 , a reaction liquid introduction channel 105 , a reaction liquid supply opening 106 , and an evacuation opening 107 .
[0032] As illustrated in FIG. 1 , the microreactor array 10 is configured by the transparent plate 101 and the transparent plate 102 bonded together. The transparent plate 101 has formed therein the reaction container 103 , the reaction liquid quantifying channels 104 and the reaction liquid introduction channel 105 . The transparent plate 102 has formed therein the reaction liquid supply opening 106 and the evacuation opening 107 . The transparent plates 101 , 102 may be, for instance, resin plates.
[0033] The reaction container 103 are formed, for instance, to a circular shape having a diameter of 500 μm and a depth of 100 μm. The reaction liquid quantifying channels 104 and the reaction liquid introduction channel 105 are formed so that the cross section thereof perpendicular to the direction of reaction liquid flow is 100 μm wide and 100 μm deep. The reaction liquid quantifying channels 104 are formed to a length of 3 mm along the direction of reaction liquid flow. The volume of the reaction container 103 is smaller than the volume of the reaction liquid quantifying channels 104 . Preferably, the reaction container 103 , the reaction liquid quantifying channels 104 and the reaction liquid introduction channel 105 are subjected to a treatment that renders the inner wall surfaces thereof hydrophilic, in order to prevent bubble adhesion. Preferably, the inner wall surfaces of the reaction container 103 , the reaction liquid quantifying channels 104 and the reaction liquid introduction channel 105 are subjected to a surface treatment that inhibits nonspecific adsorption of biomolecules such as proteins. Also, the surfaces of the transparent plate 101 and the transparent plate 102 that come into contact with each other are preferably subjected to a surface treatment for imparting liquid repellency, with a view to preventing contamination across neighboring reaction container 103 during preliminary application of primers and fluorescent probes, necessary for PCR reactions, on the reaction container 103 .
[0034] A method of filling reaction liquid into the microreactor array 10 is explained next.
[0035] Firstly, as illustrated in FIG. 2 , the microreactor array 10 is placed in an airtight container 20 provided with a pressure gauge 23 , and then the pressure is reduced to 60 kPa by way of a vacuum pump 21 . Thereby, the pressure inside the microreactor array 10 (inside the reaction container 103 , the reaction liquid quantifying channels 104 and the reaction liquid introduction channel 105 ) is brought down to 60 kPa. A syringe pump 22 for reaction liquid filling is connected to the reaction liquid supply opening 106 of the microreactor array 10 . With the pressure in the airtight container 20 kept at 60 kPa, the reaction liquid is fed into the reaction liquid introduction channel 105 using the syringe pump 22 .
[0036] The reaction liquid includes a target nucleic acid, a polymerase and nucleotides (dNTPs) at predetermined concentrations suitable for reaction.
[0037] As the target nucleic acid there may be used, for instance, DNA extracted from biological samples such as blood, urine, saliva or spinal fluid, or cDNA reverse-transcribed from extracted RNA.
[0038] The primers may be present in the reaction liquid, although in the microreactor array of the present example the primers are applied beforehand on the reaction container 103 , where they are held in a dry state. Different primers may be applied on respective reaction container 103 , so that multiple PCR reactions can be carried out simultaneously.
[0039] Reduction of pressure in the microreactor array 10 may also be accomplished by directly connecting the vacuum pump 21 to the evacuation opening 107 , as illustrated in FIG. 3 , without resorting to an airtight container 20 such as the one illustrated in FIG. 2 .
[0040] Next, the pressure inside the microreactor array 10 is brought back to atmospheric pressure. At the stage in which reaction liquid is fed into the reaction liquid introduction channel 105 , the reaction liquid lingers in the reaction liquid introduction channel 105 without flowing into the reaction liquid quantifying channels 104 , as illustrated in FIG. 4A . The purpose of this is to balance capillary forces and atmospheric pressure in the reaction liquid quantifying channels 104 and the reaction container 103 connected thereto. When the pressure inside the microreactor array 10 is reverted to atmospheric pressure, a given amount V of reaction liquid flows from the reaction liquid introduction channel 105 into the reaction liquid quantifying channels 104 , as illustrated in FIG. 4B . The liquid amount V is the amount of reaction liquid that ultimately fills the reaction container 103 .
[0041] Herein, the relationship of equation (1) below holds-initially:
[0000] V /( V 1 +V 2)=( P 0 −Pc )/ P 0 (1)
[0042] wherein Pc denotes the set pressure (in this case 60 kPa) when the interior of the microreactor array 10 is evacuated, V 1 denotes the volume of the reaction container 103 , V 2 denotes the volume of the reaction liquid quantifying channels 104 , P 0 denotes the atmospheric pressure (≈100 kPa) and V denotes the amount of reaction liquid introduction from the reaction liquid quantifying channels 104 into the reaction container 103 .
[0043] The liquid amount V can thus be obtained from equation (2) below.
[0000] V =( V 1 +V 2)×( P 0 −Pc )/ P 0 (2)
[0044] Assuming P 0 =100 kPa, and since Pc=60 kPa, reaction liquid flows into each reaction liquid quantifying channel 104 in an amount of equivalent to 40% of the aggregate volume (V 1 +V 2 ) of the reaction container 103 and the reaction liquid quantifying channels 104 .
[0045] Preferably, the set pressure Pc ranges from 50% of the atmospheric pressure P 0 to less than the atmospheric pressure P 0 .
[0046] By setting thus the pressure Pc to range from 50% of the atmospheric pressure P 0 to less than the atmospheric pressure P 0 , the amount of liquid introduced from the reaction liquid introduction channel 105 into the reaction liquid quantifying channels 104 is no greater than 50% of the aggregate volume (V 1 +V 2 ) of the reaction container 103 and the reaction liquid quantifying channels 104 . Setting V 1 <V 2 , as described above, and keeping the amount of liquid flowing into the reaction liquid quantifying channels 104 within the above range has the effect of preventing the reaction liquid from reaching the reaction container 103 . If the reaction liquid flows into the reaction container 103 , the reagent applied beforehand in the reaction container 103 may leach out into the reaction liquid, which may result in contamination across neighboring reaction container 103 via the reaction liquid quantifying channels 104 and the reaction liquid introduction channel 105 .
[0047] Next, the reaction liquid remaining in the reaction liquid introduction channel 105 is suctioned off and removed using a syringe or the like, as illustrated in FIG. 4C . Subsequently, the reaction liquid supply opening 106 and the evacuation opening 107 are sealed with adhesive sheet or the like, and the microreactor array 10 is rotated using a centrifugation device 30 such as the one illustrated in FIG. 5 .
[0048] The microreactor array 10 is placed on a rotary table 31 of the centrifugation device 30 , as illustrated in FIG. 5 . Rotation of the centrifugation device 30 causes then centrifugal force to act in the microreactor array 10 , in the direction running from the reaction liquid quantifying channels 104 towards the reaction container 103 .
[0049] The reaction liquid in the reaction liquid quantifying channels 104 moves into the reaction container 103 as a result of the centrifugal force acting on the microreactor array 10 . The specific gravity of the air in the reaction container 103 is smaller than that of the reaction liquid, and hence the air in the reaction container 103 is pushed out into the reaction liquid introduction channel 105 via the reaction liquid quantifying channels 104 . Air is thus replaced with the reaction liquid, which fills as a result the reaction container 103 .
[0050] PCR (biological sample reaction treatment) is carried out then, once the reaction liquid is fed into the microreactor array 10 in accordance with the above procedure. To carry out the PCR process, the transparent plate 102 is fixed at a predetermined position and the microreactor array 10 is placed in a thermal cycler. PCR involves ordinarily repeating cycles that has each a step of denaturating double-stranded DNA at 94° C., a subsequent step of annealing with primers at about 55° C., and a step of replicating complementary strands, at about 72° C., using a thermostable DNA polymerase.
[0051] When real-time PCR is to be carried out in the microreactor array 10 , the inner walls of the reaction container 103 are coated beforehand with fluorescent probes and the primers used in the PCR reaction, with fluorescence intensity being measured at each cycle using a CCD sensor or the like. The amount of initial target nucleic acid is calculated and measured on the basis of the cycle at which a specific fluorescence intensity is reached. The method for carrying out real-time PCR is not limited to the above one. For instance, fluorescent probes may be rendered unnecessary when using a double-strand binding fluorescent dye such as SYBR(™) Green.
[0052] In Embodiment 1, thus, centrifugal force is used to feed reaction liquid into the reaction container 103 via the reaction liquid quantifying channels 104 . Reactions using extremely small amounts of reaction liquid are made possible thereby, something that is difficult to achieve by pipette quantifying. Moreover, the reactions can take place in multiple reaction container 103 at a time, which allows conducting multiple tests with good efficiency.
[0053] The reaction liquid is introduced into the reaction container 103 after having resided in the reaction liquid quantifying channels 104 , whereby contamination across reaction container 103 can be prevented.
[0054] In Embodiment 1, the microreactor array 10 is used in a reaction apparatus for real-time PCR, but may also be used for various reactions that utilize genetic or biological samples. For instance, the microreactor array 10 may be used in a process for detecting target proteins in a reaction liquid, by coating the reaction container 103 with, for instance, peptides (oligonucleotides) or proteins such as antigens, antibodies, receptors or enzymes that selectively capture (adsorb or bind to) specific proteins.
|
A biological sample reaction chip, including: a plurality of reaction containers; a reaction liquid introduction channel having a reaction liquid supply opening at a first end and an evacuation opening at a second end; and a reaction liquid quantifying channel, a third end of which is connected to one of the reaction containers, and a fourth end of which is connected to the reaction liquid introduction channel, wherein an interior of each of the reaction containers is coated with a reagent that is necessary for a reaction.
| 1
|
RELATED PATENT APPLICATION
This application claims the benefit of U.S. Provisional Application No. 60/200,835, filed May 1, 2000 and entitled “Passive Spinal Fusion Diagnostic System”.
TECHNICAL FIELD OF THE INVENTION
This invention relates to devices for measuring displacement, and more particularly to a wireless device that can be implanted between two adjacent objects and used to measure changes in their separation distance.
BACKGROUND OF THE INVENTION
Displacement and proximity sensors play large roles in the automotive, aerospace, food, beverage, metal, and computer industries. The increase in automation has vastly increased the demand for such sensors. This demand is due to the replacement of outdated plant equipment and the overall increase in factory automation.
Of the sensors in the proximity and displacement sensor market, inductive (magnetic) and photoelectric sensors are probably the most popular. Other types of displacement sensors are capacitive sensors, ultrasonic sensors, potentiometric sensors, laser sensors, and ultrasonic sensors.
Magnetic displacement sensors include LVDT (linear variable differential transform) sensors, hall effect sensors, and magnetostrictive sensors. LVDT sensors use three coils, a primary coil and two secondary coils. The secondary coils are connected to establish a null position. A magnetic core inside the coil winding assembly provides a magnetic flux. When the core is displaced from the null position, an electromagnetic imbalance occurs. Hall effect sensors are based on a voltage that is generated in one direction when a current and a magnetic field pass through semiconductor material in the other two perpendicular directions.
Variations of magnetic and inductive sensors have been developed with one or two coils. A disadvantage of many magnetic and inductive designs is the need for an electrical connection to the sensor.
SUMMARY OF THE INVENTION
One aspect of the invention is a sensor/interrogator system for measuring displacement between two adjacent objects. The sensor has a magnetic rod, a sensor coil, and a capacitor attached to the sensor coil so as to form a tuned circuit. A first end of the rod is insertable into a first end of the coil and moveable along the axis of the coil. The rod has an end mount at its second end, as does the coil, which permits the sensor to be attached between the two objects. When the objects move, the rod moves along the coil. The interrogator having at least one interrogator coil, transmit circuitry for delivering to the sensor coil an excitation signal through a range of frequencies, and receive circuitry for receiving a response signal from the sensor coil. The change in frequency of the response signal is related to the amount of motion of the rod inside the coil.
For orthopedic applications, an advantage of the invention is that it provides a non-invasive system that incorporates an implantable passive sensor and an external interrogating device. The system is especially useful to diagnose spinal fusion postoperatively, by measuring the changes in separation of the vertebrae. The sensor response can be correlated to the relative motion of the vertebrae. The system can also be used for diagnosing other types of bone fusion, such as motion between an orthopedic implant and the surrounding bone. Small motions in this case, indicate implant loosening. The system can also measure motion between two bone segments of a fracture. Small motions in this case, indicate non-fusion of the fracture.
For spinal fusion applications, when a patient postoperatively complains of pain, the physician needs to determine whether the pain is the same as the preoperative pain or if it is from a different source. The sensor/interrogator system may be used to diagnose whether the spine has fused (a new source of pain must be the cause) or not (the same area may be causing the pain). This determination will affect the patient's treatment. In addition, as the patient is monitored postoperatively, the physician can use the information from the system to guide the patient's rehabilitation program, allowing a faster recovery time and reduced healthcare costs. In the past, methods to diagnose spinal fusion have used radiographic tools. In contrast, the system described herein does not need radiography, and allows the physician to diagnose spinal fusion in his or her office.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a sensor in accordance with the invention, affixed between two vertebra of the human spine.
FIG. 2 illustrates a sensor similar to that shown in FIG. 1, with its rod and coil separated.
FIG. 3 illustrates the sensor of FIG. 2, with its rod inserted into the coil, and with the addition of a protective sheath.
FIG. 4 illustrates the placement of an interrogator used to transmit an excitation signal to the sensor and receive a response signal from the sensor.
FIG. 5 illustrates one implementation of the circuitry of the interrogator of FIG. 4 .
FIG. 6 illustrates an example of the signal receive circuitry of the interrogator of FIG. 5 .
FIG. 7 illustrates a two-coil embodiment of the interrogator of FIG. 4 .
FIG. 8 illustrates a three-coil embodiment of the interrogator of FIG. 4 .
FIG. 9 illustrates the relationship of the sensor frequency response, as detected by the interrogator, and the displacement of the sensor rod relative to the sensor coil.
FIG. 10 illustrates a sensor-pair configuration, which may be used as an alternative to the sensor of FIG. 1 .
FIG. 11 illustrates an application of the sensor-pair of FIG. 10 .
DETAILED DESCRIPTION
Single Sensor Configuration
FIG. 1 illustrates a displacement sensor 10 in accordance with the invention. In the example of FIG. 1, sensor 10 is used to measure displacement along the human spine and is implanted within the lumbar spine. Sensor 10 is comprised of rod 12 , coil 13 , capacitor 14 , and end mounts 15 .
Sensor 10 is particularly useful in environments in which wires and other types of electrical leads are impractical. As explained below, to obtain a displacement measurement, an interrogator device (not shown in FIG. 1) is placed near sensor 10 . In the orthopedic application of FIG. 1, where sensor 10 is implanted, the interrogator device is external to the body.
The orthopedic application of FIG. 1 is but one application of sensor 10 . In general, sensor 10 could be implanted between any two objects and used to noninvasively measure the displacement between them. For example, for structural applications, sensor 10 could be placed between blocks of a bridge or building. The size and robustness of sensor 10 is easily scaled to the type of application and to the environment in which it is to be used.
Regardless of the application, the objects whose displacements are to be measured are “adjacent” in the sense that an end mount 15 of sensor 10 may be attached to each object. The only limitation is that the end mounts 15 of sensor 10 each be affixed in a manner that permits sensor 10 to “bridge” the two objects and that permits coil 13 and rod 12 to move relative to each other if the objects move. The term “objects” is used herein in the broadest sense; the two “objects” between which sensor 10 is attached could be two surfaces of two different pieces of material or two surfaces of a single piece of material.
End mounts 15 are at either end of sensor 10 . Each end mount 15 is attached to one of two objects whose displacement is to be measured. In the example of FIG. 1, end mounts 15 are ball joints. Motion is measured along a single axis—that of the sensor 10 . There may be more degrees of freedom, but only axial motion is sensed. Screws are used to attach the end mounts 15 to the vertebrae through holes in end mounts 15 .
FIGS. 2 and 3 illustrate sensor 10 with its coil 13 and rod 12 segments separated and coupled, respectively. In FIG. 2, sensor 10 is shown without end mounts. FIG. 3 further illustrates a flexible sheath 21 , which may be placed over rod 12 , coil 13 , and capacitor 14 . Sheath 21 is typically used when sensor 10 is implanted for biomedical applications, such as the orthopedic application of FIG. 1 .
In operation, as explained below, the motion of rod 12 within coil 13 can be correlated to the relative motion of the two objects to which sensor 10 is attached. In the example of FIG. 1, the motion of rod 12 within coil 13 can be correlated to lumbar spine motion and therefore to spinal fusion success. Sensor 10 may be positioned between any two vertebrae involved in the spinal fusion or on the ends of a spinal fusion segment. More than one sensor 10 could be implanted. Sensor 10 can be attached to the anterior or anterolateral spine or the vertebral body. Sensor 10 can be attached to the posterior spine on either the spinous processes, transverse processes or the facets. Alternative attachment sites may be necessary given the specific anatomy of a patient. In the example of FIG. 1, sensor 10 is attached to the spinous processes.
A vast variety of attachment mechanisms can be used as end mounts 15 , such as rivets, epoxy, or spring mechanisms. End mounts 15 may themselves be some type of screw or insertion post. For some applications, the attachment means should rigidly attach sensor 10 to the objects whose displacement is to be measured, minimizing any relative motion between sensor 10 and the objects to which it is attached. For other applications, end mounts 15 might be in the form of a loop or bushing that permits slight misalignment.
Rod 12 is oriented along the direction of expected motion and travels along the longitudinal axis of coil 13 as motion occurs. Rod 12 is made from a magnetically permeable material such as ferrite. The optimum rod size can be determined experimentally and depends on the application; sensor 10 is easily scaled in size for different applications. The optimum rod size may involve a tradeoff between the size of the objects whose displacement is to be measured, their expected displacement, and the distance between sensor 10 and the external interrogator device.
For orthopedic applications, rod 12 will typically range in length from one-half inch upwards, depending on where it is attached to the spine. Its diameter will usually range from one-eighth to one-quarter inch.
Coil 13 is comprised of coiled wire, the diameter of which again depends on the application and other dimensions of sensor 10 . The inner diameter of coil 13 is slightly larger than the outer diameter of rod 12 . For best performance, the length of coil 13 may range from three-quarters the length of rod 12 to twice as long as rod 12 .
For orthopedic applications, a typical range of wire diameters is 28 AWG (American Wire Gauge) to 40 AWG. The dimensions of coil 13 might range from one-fourth to three-quarters inch long by one-eighth to three-eighths inch in internal diameter. For other applications, the dimensions of coil 13 again depend on considerations such as the environment in which sensor 10 is placed and on the expected distance from the external interrogator device.
Capacitor 14 is attached to coil 13 , and is chosen to set the resonant frequency of sensor 10 . A typical frequency range for various applications is 1 to 10 MHz. For this frequency range, the size of capacitor 14 might range from 50 pF to 0.01 μF.
A suitable capacitor size for spinal fusion applications has been determined experimentally as 220 to 1000 pF. However, for other applications, the capacitor size depends on considerations such as the maximum allowable size of the coil 13 , desired resonant frequency of sensor 10 , and the need to minimize the effects of stray capacitance on the resonant frequency.
Sensor 10 uses a tuned radio frequency circuit to achieve displacement measurement. The resonant frequency (f) is set by the value of an inductance (L) and the capacitance (C) of capacitor 14 , and is given by: f = 1 2 π LC
The inductance is determined by the plunge depth of rod 12 , which, in turn, is determined by the spacing between the two objects to which sensor 10 is attached.
Means other than a capacitor 14 external to coil 13 may be used to provide a resonant circuit. For example, the coil 13 could be made self resonant. Alternatively, it could be resonated with stripline, with a gyrator, or with a capacitor in the interrogator unit. Furthermore, although resonance improves the output signal, the concept of measuring relative displacement remotely using a variable magnetic coupling between two magnetically active objects may be implemented without resonance.
Sensor 10 is passive in that no battery or other energy source is required to power it. When excited by the interrogator device, its tuned circuit absorbs and re-radiates a signal at the sensor resonant frequency. The resonant frequency changes as the plunge depth of the rod 12 changes. This permits displacement of rod 12 within coil 13 to be inferred and used to measure displacement between the objects. For the application of FIG. 1, the spacing between vertebrae is inferred from a measurement of the resonant frequency of the tuned circuit.
For biomedical applications, such as the spinal application of FIG. 1, sensor 10 might be desired to be biocompatible. These considerations call for the use of biocompatible materials for each component, coating the components with a biocompatible material, or covering sensor 10 with a biocompatible cover to achieve biocompatibility. One of these methods, as well as any combination of these methods, can be used. The method chosen should not interfere with the ability of rod 12 to move within coil 13 .
Another consideration for biomedical and other applications that call for sensor 10 to be placed in a fluid environment, is the need to prevent shorting between the elements of sensor 10 . A sheath, such as sheath 21 of FIG. 3, may be desirable to prevent shorting and permit proper functioning. Sheath 21 may be fabricated as a rubber or plastic sleeve, latex tubing, or heat shrink coating. Biocompatible materials similar to those used for angioplasty could be used.
A feature of sensor 10 is that it does not interfere with normal motion of the objects to which it is attached. Specifically, for orthopedic applications, sensor 10 does not compromise the normal kinematics of the body. Sensor 10 may be attached to anatomic positions such as the spinous process or facet that will not interfere with spine motion. In addition, sensor 10 can be used with implanted fixation devices such as pedicle screw fixation systems or spinal fusion cages and can be viewed radiographically.
Interrogator
FIG. 4 illustrates interrogator 40 , placed against a patient's back during displacement measurement. Thus, for orthopedic or other biomedical applications, sensor 10 may be internal to the body, whereas interrogator 40 is external and introduced only when measurements are desired. Thus, in general, sensor 10 is not disruptive to normal movement or operation of the environment in which it is used; interrogator 40 need only be in place when measurements are to be obtained.
During a measurement session, interrogator 40 is placed proximate to sensor 10 . To obtain a displacement measurement, interrogator 40 “reads” sensor 10 using an interrogation coil or set of coils and appropriate circuitry.
The distance between interrogator 40 and sensor 10 need not remain constant in order for the system to work correctly. An increase in separation distance will result in a reduced signal, but will not affect the frequency response.
FIG. 5 is a block diagram of one example of interrogator 40 . It has an interrogation coil 51 , a mutual inductance bridge 52 , signal transmit and receive circuitry 53 , a swept frequency source 56 , and a driver 57 .
During a measurement session, interrogation coil 51 is placed sufficiently near sensor 10 so as to loosely couple the sensor coil 13 and interrogation coil 51 . The interrogation coil 51 is driven by the swept frequency source 56 through the mutual inductance bridge 52 over a frequency span that encompasses the range of possible resonant frequencies of sensor 10 . This frequency range is bounded by the frequency associated with minimum displacement and the frequency associated with maximum displacement of rod 12 relative to coil 13 . As the frequency sweeps through the resonant frequency of sensor 10 , sensor 10 absorbs and re-radiates energy, resulting in a change in the output of the mutual inductance bridge 52 .
FIG. 6 illustrates an example of signal transmit and receive circuitry 53 . It has a signal detector circuit 61 , an analog to digital converter 62 , a microcontroller 63 , memory 65 , and a data output interface 64 . Its functions include control of the swept frequency source 56 , calibration of the mutual inductance bridge 52 , extraction of the measured data, and formatting of the user output display.
In the example of FIGS. 5 and 6, frequency source 56 is a commercially available integrated circuit, but other types of frequency generation techniques may be implemented. At the receive side of interrogator 40 , the output of frequency source 56 may be mixed with the received signal for coherent detection. The amplitude of the resulting signal will then vary with frequency. This mixing technique is useful to enhance the signal to noise ratio and sensitivity of the interrogator.
In the example of FIG. 5, coil 51 is a single coil loop antenna that transmits an excitation signal to coil 13 and receives a response signal. In other embodiments, multiple coils (transmit and receive) could be used. Various AC coupling or mechanical nulling techniques can be used to minimize the offset portion of the signal. This permits increased gain of the received signal, and thereby increases the sensitivity of interrogator 40 .
FIG. 7 illustrates another example of interrogator 40 . Two coils 71 and 72 are arranged in a hull coupling geometry. The coils 71 and 72 are overlapped side by side at the critical coupling spacing so that the field from the transmit coil 71 nulls that of the receive coil 72 . A differential amplifier 73 receives and amplifies the output of the receive coil 72 .
FIG. 8 illustrates a three coil geometry of the interrogator 40 . Coil 81 is a transmit coil. Two receive coils 82 are connected as a differential receiver and cancel the transmitted signal. A differential amplifier 83 measures the difference between the positive signal from one receive coil 82 and the equal in amplitude but opposite in phase signal from the other receive coil 82 , and provides an amplified output of the difference.
For the interrogator embodiments of FIGS. 7 and 8, interrogation is accomplished by loosely coupling to sensor 10 and sweeping the frequency over the anticipated resonant frequency of the sensor. The transmit coil 71 or 81 and receive coil(s) 72 or 82 can both couple to sensor coil 13 , but not to each other. As the frequency sweeps through the resonance of sensor 10 , energy is coupled from the transmit coil 71 or 81 to the receive coils(s) 72 or 82 via the sensor's tuned circuit. The output of the receive coil(s) 72 or 82 is detected and processed as before.
FIG. 9 illustrates the relationship between the frequency response of sensor 10 , as detected by interrogator 40 , and the relative displacement of rod 12 relative to coil 13 . This graph shows that displacements of approximately 0.1 mm can be resolved.
Sensor Pair Configuration
FIG. 10 illustrates an alternative sensor configuration, comprised of a pair of sensors 100 . Each sensor 100 has a rod 102 , a coil 103 , and a capacitor 104 . Like sensor 10 , the rod 102 , coil 103 , and capacitor 104 form a tuned circuit. However, unlike the rods of sensors 10 , the rod 102 of a sensor 100 does not move relative to its coil 13 . It is the displacement between sensors 100 that is of interest.
Sensors 100 are used to measure the displacement between any two locations. One sensor 100 is attached or embedded at one location, and the other sensor 100 to a nearby location.
One advantage of the configuration of FIG. 10 is that the sensors 100 can be mounted independently, with no physical connection between the two. However, the sensors 100 should be initially placed sufficiently close together and in the correct orientation so as to form the overcoupled system described below. In general, the sensors 100 are placed substantially parallel to each other and offset axially.
Like sensor 10 , sensors 100 may each have end mounts (not shown). Furthermore, an end mount might be at only one end rather than at both ends. However, an advantage of the configuration of FIG. 10 is that sensors 100 may be simply embedded within an object or within each of two different objects; there is no need for mechanical coupling of sensors 100 .
For the sensor embodiment of FIG. 10, two tuned circuits are used, both to the same resonant frequency. Sensors 100 have a fixed frequency response. When placed in proximity to one another, the tuned circuits of sensors 100 interact and form an overcoupled resonant system. Rather than a single resonant peak, there is a double peak. The frequency separation between the peaks is sensitive to the spacing between the two sensors 100 . Relative motion between the sensors 100 is detectable by a shift in peak separation.
FIG. 11 illustrates the application of sensors 100 for measuring spinal fusion. Rods 102 are threaded on the end to allow them to be screwed directly into the spine. If a large area of the spine is of interest, numerous sensors 100 could be implanted. The relative motion of sensors 100 can be correlated to spine motion and therefore spinal fusion success.
The sensor-pair configuration of FIGS. 10 and 11 can be interrogated with an interrogator that is similar to interrogator 40 . The primary difference is that the data is inferred from the frequency separation of a double peak response instead of the location of a single resonant peak.
Orthopedic Applications
In practice, for orthopedic applications, one or more sensors 10 are implanted during surgery. The length of rod 12 is chosen so that at rest, rod 12 is positioned within coil 13 only one-quarter to three-quarters the length of rod 12 . For the sensor-pair configuration of FIG. 10, the two sensors 100 are placed parallel to each other and offset axially.
When the patient visits the physician, the interrogator 40 is secured to the patient. It is placed sufficiently close to the patient such that the distance between the sensor 10 (or sensors 100 ) and the interrogator 40 is minimized. As the patient moves, the internal sensor 101 frequency response changes will be measured and correlated to motion.
For the spinal fusion application of FIG. 1, theoretically, if the spinal fusion surgery was successful, there should be no measurable motion between the spinal fusion segments. The changes in the sensor response can then be correlated to relative motion of the vertebrae and to spinal fusion success. Unlike flexion-extension x-rays and CT scans which measure a static position and compare it to another static position, sensor 10 and interrogator 60 can dynamically measure motion and any sensor response changes can be correlated to fusion success. Dynamic measurement and analysis of motions are completed through automated data analysis, allowing the physician to see the outcome of the diagnostic test immediately after the test is completed. Therefore, the spinal fusion healing progression could also be objectively observed over time.
The same system can be used for diagnosing other types of bone fusion. For instance, the system can measure motion between an orthopedic implant and the surrounding bone. Small motions in this case would indicate implant loosening. The system can also measure motion between two bone segments of a fracture. Small motions in this case would indicate a non-fusion of the fracture. Therefore, the invention provides a very simple and consistent measuring system for diagnosing small motions between bones or between orthopedic implants and bone surfaces without being invasive. In general, the sensors are attached to “skeletal objects” whether they be natural or artificial.
Other Embodiments
Although the present invention has been described in detail, it should be understood that various changes, substitutions, and alterations can be made hereto without departing from the spirit and scope of the invention as defined by the appended claims.
|
A system that remotely measures displacement between two objects. A passive sensor is affixed between the objects. The internal sensor uses magnetic coupling between two sensor elements to measure their relative displacement. The sensors are either a) a permeable rod and a complimentary coil in parallel with a tuning capacitor; or b) two permeable rods, each having its own surrounding coil and a tuning capacitor. One of the sensor elements is affixed to each object which is to be monitored. When an interrogating device is placed near the sensors, a resonance can be measured whose frequency characteristics change in a reproducible manner with the relative displacement of the sensors. The resulting resonance characteristics can be calibrated in such a way as to enable the displacement of the objects to be determined.
| 0
|
BACKGROUND OF THE INVENTION
The present invention is in the field of assembly systems for articles made of limp material, and more particularly related to sewing machines.
Sewing machines are well known in the prior art to join portions of a multiple layer limp fabric (or material) workpiece along a curvilinear path, thereby forming a seam. Generally, such machines include a needle adapted for reciprocating motion along a needle axis which is angularly offset from a planar workpiece support surface. In most prior art sewing machines, manually or automatically controlled, feed devices present the fabric-to-be-joined to the needle along a feed axis which is fixedly positioned with respect to the needle axis and the workpiece support surface. By way of example, such devices include feed dogs, rolling cylinder feeds and tractor feeds (using endless belts over rollers).
Robots have long been applied successfully throughout industry in a variety of applications as diverse as welding, painting and assembly. By far the most challenging of these applications has been assembly. A significant amount of Progress has been made in improving the ability of robots to accomplish complex assembly tasks but for the most part research has concentrated on assembly of rigid parts made of hard plastic and metals, materials typically found in assembly of small mechanical or electrical devices. Much less research has been directed towards the assembly of flexible parts such as textiles. Development of flexible material handling technology is necessary in order to introduce robotics into industries based on flexible, or limp, materials, such as apparel manufacturing.
Since textiles are flexible materials, they pose problems for robotic manipulation which were not encountered in rigid parts manipulation. The inherent limpness of textiles necessitates design of specialized handling equipment to assure that the flexible workpiece does not distort during handling. This equipment must be designed to be robust to material properties which affect handling that vary not only from part to part, but also within a single part.
In recent years, there have been significant advances in the automated control of limp material segments, particularly suited for apparel manufacture. By way of example, U.S. Pat. Nos. 4,632,046, 4,607,584, 4,719,864, 4,651,659 and 4,638,749, all assigned to the assignee of the present invention, disclose systems and methods for manipulating and controlling limp material segments generally for presentation to seam joining assemblies, e.g. sewing machines. All of these patents are concerned with the fact that the limp materials are easily deformed. Since the edges of cloth panels which must eventually be aligned are easily deformed, multiple support points are required. Typically, the support points must be placed close enough to the desired edge so that distortions such as curling or folding do not occur during transport. The placement is further complicated by the fact that the cloth's tendency to curl, fold, or wrinkle is highly dependent on material properties such as bending rigidity. Bending rigidity will vary from part to part as material changes (e.g. polyester or wool) and can even vary within a single part, depending on orientation of the gripper to the weave or proximity of the gripper to reinforcements. During manipulation of flexible materials, such as textiles, little force is transmitted back t the positioning device, since the workpiece is easily distorted. As a result, non-contact sensing methods such as vision are often utilized for final alignment before establishing a seam.
U.S. Pat. No. 4,719,864 discloses a feed assembly for a sewing machine which provides near needle control of the segments-to-be-joined.
In connection with automated sewing systems, it has proved to be very difficult to get the ends of a long seam to match up when two plies are sewn together. Slight errors in differential feeding of the two plies to the needle accumulate to large errors by the end of a long seam. Other sources of errors result from uneven drag on the cloth and from mis-cut lengths of material. When the seam is sewn by hand, measures can be taken to correct any noticed misalignment. However, automatically sewn seams using prior art systems generally have large errors if no correction method is used.
Moreover, in many sewing applications, cloth panels cannot always be held firmly in place during the sewing operation since for proper alignment to occur the two cloth parts must be allowed to move in the direction parallel to the seam direction. This motion is accomplished by "ply shifting", i.e. moving one ply relative to another, during the seaming operation. In the simplest case, when two seams are joined, no ply shifting is introduced resulting in a flat seam after sewing. If one ply is shifted relative to another during sewing, then bunching occurs, This effect, known as easing, may be selectively utilized to shape garments during seaming.
In the prior art, several methods have previously been used to control end alignment and easing. The most common method is to use a human operator, together with workpieces having reference notches cut into the edges of the segments-to-be-joined, where the notches are positioned to overlap when the seam is properly established with desired easing. As the operator hand sews, he attempts to align the notches. This operation requires great skill but is tedious and characterized by relatively low productivity. Further, good operators are hard to find.
Alternatively, automatic machines without end feedback are used, where end alignment control is manually adjusted during sewing so that the ends visually line up after seaming. However, slight variations in material properties can cause end aligning errors. This problem becomes amplified with longer seams.
More recently, sewing systems have used a single "mouse" whereby both ply end corners (at the end of the desired seam-to-be-made) are clamped together prealigned. The workpiece bearing the opposite end of the seam is then drawn toward the needle while the mouse is dragged along to maintain tension and to assure the trailing ends line up. The main problem with this method is that the easing profile throughout the seam is not well controlled. Normally, if plies are miscut, it is considered best to put constant, minimal, easing all along the seam to correct for the length error. However, with the single mouse system (due to properties of feed dog mechanisms), a high amount of easing is generally established at the beginning of the seam, and the easing typically drops to zero easing by the end of the seam. In attempting to overcome this deficiency, some single mouse machines have a differential feed mechanism where an easing profile can be programmed for the entire length of the seam. The problem with this approach is that such easing is accomplished in an open loop manner and any easing caused by the mouse is uncontrolled.
Accordingly, it is an object of the present invention to provide an improved system for establishing a seam joining two (or more) limp material segments.
Another object is to provide an improved seam joining system permitting establishment of seams with continuous control of the regions of the materials being joined.
It is another object to provide an improved seam joining system in which distal ends of the materials-to-be-joined are controlled during the joining operation.
Yet another object is to provide an improved seam joining system permitting predetermined easing to be incorporated on a continuous basis during a seam joining operation.
Still another object is to provide an improved seam joining system permitting predetermined easing to be incorporated in both workpieces-to-be-joined.
SUMMARY OF THE INVENTION
The invention includes a sewing machine, two trackers (mice) to track the ends of material-to-be-joined, and a controller for controlling stitch formation to achieve precise control of the material position, permitting desired easing (positive or negative). A long table is used with a separation plate so that the two panels-to-be-joined can be laid out flat and separated during sewing. The mice slide in tracks so they will move in a straight line. The mice are attached by geared cables to motors so that tension can be maintained if desired and so that the mice can be pulled back when the seam is done. Optical encoders are geared to the cables so that the position of the mice, and thus endpoints of the panels, can accurately be determined.
The sewing machine has an attachment that provides differential feed of the two plies. The differential feed rate is adjusted under control of the controller by a servo motor attached to the differential feed control lever on the sewing machine.
The two optical encoders and a stitch count sensor are monitored by the controller as sewing progresses. From the sensor information, the controller controls seam alignment in the sewing direction through control of the mouse motor torque and/or the differential feed control motor.
Briefly, the sequence of events to control seam end alignment is as follows:
a) Operator places leading edge corners of the overlapped panels accurately under presser foot and trailing edge corners are accurately affixed to a respective mouse clamp. This operation may be accomplished either manually or automatically.
b) After loading, automatic sewing may be started. Initially, mouse cable tension is brought up to a desired value, such as one pound, for a few seconds and then relaxed. This operation pulls out any wrinkles and allows the controller to record stretched length and relaxed length of the material. The controller also calculates spring rate from this data.
c) The controller then determines a sewing profile that will nominally make the ends line up and also satisfy any easing requirements given by the operator.
d) The sewing machine then starts sewing. At each stitch, the controller determines from the mouse positions whether the seam profile is being sewn correctly and, if not, takes corrective measures by changing the differential feed or changing the drag tension.
e) When the end of the seam is reached, the material is removed from the clamps.
The primary advantage of the invention is that the trailing ends of a seam are monitored throughout the entire seaming operation. This allows alignment of the trailing ends with a minimum of differential feeding. There are several alternate methods of sensing the end positions:
Sensors in table--Rather than using mice to sense end positions, several light sensors may be mounted in the table top to detect when material passed by. This provides periodic updates of the end positions. By way of example, light sensors spacing of about six inches gives satisfactory results in most applications.
Belts--If both plies can be deformed into a straight line along the seam, then they can be held in place by long belts prior to sewing. As the sewing machine sews, the belts can incrementally deliver the material. The two advantages of this method is that the end positions can be known without material springrate affecting accuracy and that loading and unloading of the material is greatly simplified. With this configuration, the belts must be synchronized with the feed dogs so that no stretching or buckling occurs.
Driven Mice--Slight changes in the drag from the mouse can severely disrupt end position sensing if the material stretches. To accommodate this sensitivity, the mice may be driven in a servo loop so that they track the material in the feed direction and restrain in the side-to-side direction.
Encoder Feed Sensing--Although a mouse can sense end position without accumulating errors, it can show errors from stitch to stitch. An encoder wheel near the feed dogs may be used to sense incremental motion precisely, providing rapid correction to feed errors while the mouse is used only for sensing actual end position.
Drag Control Near Needle--Where drag is used to control feed, that drag may be established near the feed dogs with a roller or drag foot. Causing drag separately near the feed dogs eliminates coupling caused by material deflection.
Edge Aligners--A separate device may be used to control edge alignment.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects of this invention, the various features thereof, as well as the invention itself, may be more fully understood from the following description, when read together with the accompanying drawings in which:
FIG. 1 shows in perspective view a seam joining system in accordance with the present invention;
FIG. 2 shows the ply separator for the system of FIG. 1;
FIG. 3 shows a side sectional view of the differential feed system of the system of FIG. 1;
FIG. 4 shows a process model for the differential feed controller of the system of FIG. 1;
FIG. 5 shows a model for the servo motor of the model of FIG. 4;
FIG. 6 shows in block diagram form the system of FIG. 1;
FIG. 7 shows in block diagram form the system of FIG. 1;
FIG. 8 shows a simplified block diagram of the feed forward LI controller of the system of FIG. 1;
FIG. 9 shows the transfer function of the system of FIG. 8;
FIG. 10 shows a root locus diagram representative of the transfer function of FIG. 9;
FIG. 11A shows an exemplary easing profile;
FIG. 11B shows the per cent (%) easing curve for the seam corresponding to the profile of FIG. 11A;
FIG. 11C shows the offset curve for seam corresponding to the profile of FIG. 11A; and
FIG. 12 shows a plot of commanded and measured offset for the seam obtained for the profile of FIG. 11A.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An exemplary seam joining system 10 embodying the invention is shown in FIG. 1. System 10 includes a sewing machine 14, a workpiece support table 16, an upper ply tracker (mouse) 18 and a lower ply tracker (mouse) 20, and a ply separator 22. The top surface 16a of table 16 is generally planar and horizontal. The sewing machine 14 includes a conventional needle assembly (indicated generally by reference designation 24) including an elongated straight needle 26 (extending along a needle axis 26a perpendicular to surface 16a), an associated driver adapted to drive needle 26 in a reciprocal motion along axis 26a and a presser foot 28 (not shown in FIG. 1). Thus, the locus of needle 26 is an elongated region extending along axis 26a perpendicular to and intersecting surface 16a. In alternate embodiments, the needle may be curved and extend along a curved needle axis. The sewing machine 14 further includes a conventional looper or bobbin assembly (beneath the table 16) adapted to interact with the thread in needle 26 to form stitches in limp material on surface 16a passing the needle locus in the direction of a feed axis 30 from an upstream end to a downstream end (i.e. right-to-left as shown in FIG. 1).
The ply separator 22 in FIG. 1 is a planar plate having smooth upper and lower principal surfaces disposed above and substantially parallel to the top surface 16a of table 16. The exemplary separator 22 of system 10 is shown in FIG. 2 with reference to the needle axis 26a and feed axis 30. That separator 22 includes portions 34a, 34b and 34c. Portion 34a is generally rectangular and extends on both sides of axis 30 from the upstream end 22a of plate 22 to a point along axis 30 just upstream of needle axis 26a.
Portions 34b and 34c are also generally rectangular, but each extends only on one side of axis 30 from the downstream end of portion 34a, i.e. so that there is a longitudinally extending gap 36 between portions 34b and 34c from a point upstream of the needle locus to the downstream end 22b of separator 22. As shown in FIG. 1, the plate 22 is positioned between upper and lower limp material segments 40 and 42, respectively, which are to be joined by system 10. The smooth surfaces of separator 20 permit relatively low friction motion of segments 40 and 42 on surface 16a.
The sewing machine 14 also includes a differential feed assembly 44 (not shown in FIG. 1) disposed adjacent to the needle assembly 24. Assembly 44 is adapted to selectively and independently advance the segments 40 and 42 in the direction of feed axis 30 past the needle locus (i.e. axis 26a). In the presently described embodiment, feed assembly 44 includes an upper feed dog 50 disposed opposite the upper surfaces of portions 34b and 34c of separator 22 and a lower feed dog 52 disposed opposite the lower surfaces of portions 34b and 34c of separator 22. Conventional drivers are provided for the feed dogs 50 and 52. Assembly 44 is shown in simplified form in FIG. 3.
Generally, the feed dog drivers establish feed dog motion in an elliptical-like path that is timed to the vertical motion of the needle 26. The feed dog motion is characterized by its feed travel (FT) and feed lift (FL), illustrated in FIG. 3 for feed dog 52. Feed travel is adjustable to set the stitch length. Feed lift allows the machine 10 to accommodate a wide variety of material weights and thicknesses. Feed dogs drive the adjacent face of cloth (40 or 42) with a high friction surface bearing teeth that are spaced and sized based on material weight or thickness. The spring loaded presser foot 28 biases the material to be sewn against the respective surfaces 34b and 34c of separator 22. The presser foot 28 has a relatively low friction, polished surface so that it does not retard the motion of the upper ply. With this feed assembly a prior art system using only a lower feed dog, easing can be imparted to a seam by methods known either as "tension control" or "drag control". By applying tension to one ply, its motion past the needle 26 is effectively retarded relative to the other ply, resulting in differential feed of the seam. However, with the present invention, in the form of system 10, easing can also be imparted to a seam through mechanical means by overfeeding a cloth ply. This can be accomplished with the "variable top feed" system that consists of the independently controlled top feed dog 50 in combination with the "conventional" lower feed dog 52. This configuration provides direct control of easing since each cloth ply 40 and 42 is in direct contact with a feed mechanism. The motion of the respective feed dogs is responsive to first and second feed signals applied (via lines 70a and 70b) to the respective feed drivers.
The trackers (or mice) 18 and 20 are positioned on slides (indicated in part by broken lines 18a and 20a in FIG. 1) in table 16, permitting linear motion along axes parallel to feed axis 30. Each of trackers 18 and 20 includes a clamp assembly (indicated schematically by reference designations 18b and 20b in FIG. 1) which may be selectively operated to clamp a portion of segments 40 and 42 adjacent to the desired seam end points to the respective ones of trackers 18 and 20. In the illustrated embodiment, each of trackers 18 and 20 is coupled by a cable (cables 60 and 62, respectively) to the input shaft (64a, 66a) of a torque motor (motors 64 and 66, respectively). The shaft position encoders for motors 64 and 66 are coupled via lines 64b and 66b to a controller 70.
In operation, the limp material segments 40 and 42 to be joined are placed in overlapping relation on surface 16a, i.e. in a plane parallel to the surface 16a. The segments are positioned so that the start points of each of the seams-to-be-formed are overlapping at a known reference point along axis 30. The motors 64 and 66 are operated to wind the cables 60 and 62 about the respective motor drive shafts so that the trackers 18 and 20 are withdrawn from the needle axis until those trackers are adjacent to the desired seam end points on the respective segments 40 and 42.
Then, the clamp assemblies of the trackers 18 and 20 are then affixed to portions of the segments 40 and 42 so that the precise location (along axis 30) of the end points of each of the seams to be formed are indicated on lines 64b and 66b. At this point, in response to feed signals generated by controller 70, the operation of differential feed assembly 44 is initiated so that the segments 40 and 42 are presented in a controlled manner to needle assembly 24, independently controlling the feed of segments 40 and 42. As this feed occurs, the trackers 18 and 20 are drawn along by the segments, and their respective encoders report (via lines 64b and 66b) the correct position of the trackers to controller 70. In response, controller 70 generates the feed signals so that the desired seam is established with the desired easing in each of the segments. All of these operations are performed under the control of controller 70 in the present embodiment.
An automated easing system which must operate in a factory environment must be responsive to changes in cloth material properties. Within a typical production run in the tailored clothing industry, material type varies from natural fabrics to synthetics, as well as to natural/synthetic blends. Material properties, such as shear stiffness, compressibility, bending stiffness, ply thickness, coefficient of friction may be different for each of these material types. As these properties change, the easing characteristics of the material are also effected. In addition, machine properties, such as presser foot pressure, feed dog height/stroke and general machine wear also affect the quality of an eased seam. In a manual/operation the prior art, a trained operator can often intuitively adjust for varying material properties and minor machine mis-adjustments by modifying the amount of tension on the eased ply appropriately. An automated system, however, must either be designed in such a way as to not be sensitive to material properties and machine wear/set-up or be programmable to adjust for variations in these parameters.
A prior art technique which improves the quality of eased seams is measurement of material properties before sewing followed by appropriate adjustment of the sewing system to compensate for material characteristics. Systems for measuring material properties such as FAST and Kawabata currently exist and have been successfully used in this matter to improve sewn seam quality. Kawabata, Dr. Sueo, "Japanese Experience: Using Fabric Mechanical Properties To Predict Tailorability And Improved Garment Appearance", Proceedings of Advanced Apparel Technologies: Blueprint for the Future pp. 73-92, Oct. 25, 1988. Unfortunately, as a sewing machine wears or falls out of adjustment the appropriate machine settings for a particular material will change. It is therefor important to not only measure material properties, but to measure the properties of the machine/material interface. The present invention utilizes feed forward control based on control parameters.
Generally, assembly of two or more cloth parts by sewing is a process that requires many specifications to assure a good quality garment. A primary such specification is the differential shift between two layers of fabric along the sewing axis. This differential shift is known as "easing" or fullness. Easing may be specified as y inches of shift over x inches of seam length. Easing may equivalently be defined as the relative strain that exists between layers of cloth in a flat seam. This is a non-dimensional number having a magnitude of a few percent. The specification may be considered as a set of curves, y=f(x) and its derivative y'=dy/dx, named respectively, offset and easing.
Using this definition of easing, the sewing machine 10 can be modeled as an integrator. As sewing proceeds, easing integrates along the seam to cause relative shift between layers, referred to as offset. The mathematical relationship between offset and easing at a point x along the seam is represented by: ##EQU1##
Thus, the sewing machine 10 can be modeled as an integrator with respect to x, which is equivalent to integration with respect to time if its speed (v) is constant. These equivalent models are: ##STR1##
A mathematical systems model of easing control using an actuated feed adjustment mechanism may be established. The actuated feed adjustment mechanism can control the individual rates with which the top and bottom plies are fed through the sewing region. The model consists of three parts: 1) the actuator, 2) the feed adjustment mechanism, and 3) the sewing machine. The block diagram of the system model, shown in FIG. 4, contains a drag disturbance d, and a feed uncertainty γ.
The sewing machine is modeled as an integrator with respect to seam position x. The feed mechanism is modeled with a nonlinear function g(u) that describes the kinematics of the differential feed adjustment mechanism. The function g(u), whether empirical or analytical. The derivative of g(u) is positive. In this model, the actuator, G a , is a D.C. electric servo motor with position feedback and PD compensation. The model of the second order system is shown in FIG. 5. The transfer function for the servo motor is shown in FIG. 6.
The compensator parameters k p and k D are uniquely determined by the desired natural frequency ω n and damping ratio ξ: ##EQU2##
Speed or material dependent variation is an uncertainty in the feed adjustment mechanism and is represented by γ in FIG. 4. Any drag placed on the fabric as il is being sewn is treated as a disturbance, and is unrelated to the control input. Drag disturbances are shown in d in FIG. 4. End position measurement is effected by drag and, the position measurement is also corrupted with noise from the intermittent feed of the sewing machine.
The process model for differential feed control at FIG. 4 consists of linear dynamic elements and a nonlinear kinematic function. Unknown disturbances and uncertainties, having bounds determined by testing, are included in the model. As described more fully below, the controller developed uses feedback to stabilize the system and to reject disturbances. Feed forward is used to reduce following error.
The feed forward command is derived directly from the process model by requiring the system to exactly follow the reference, given that the actuator is sufficiently fast to track the reference. A linear approximation to the nonlinear feed adjustment function g(u) is used with γ and d considered to be unknown. ##EQU3##
A feedback loop is used to stabilize the system since uncertainties integrate to arbitrarily large error. The block diagram of the system is shown in FIG. 7, with transfer functions G c and H s for the compensator and sensor, respectively.
The control of offset y is merely a specification of the more critical control variable easing y'. In order to obtain a "quality" seam, easing must be evenly placed, resulting in a specified offset. A "poor" seam may meet offset specifications, but have unevenly distributed easing. The system filters noise contained in the feedback signal to insure seam quality.
The intermittent feed motion of the sewing machine is a source of high frequency noise, typically greater than 60 Hz. The high frequency content of d 1 is filtered by the integrator, so, very little effect on feedback is anticipated. The high frequency content of d 2 is filtered by the sensor provided it has adequate damping. Otherwise, the sensor generates noise at its resonant frequency.
Devices near the sewing machine such as edge aligners, folders, or sensors may impose constant and/or sudden drag disturbances. The effect of these disturbances on the process may be significant, but the closed-loop system substantially eliminates them over time. The effect on the feedback loop may be insignificant provided that the distorted length of material is short. However, for long seams, disturbance far from the sewing machine may result in a significant length variation.
A simple proportional compensator is used to stabilize the system, with the gain selected to compromise between disturbance rejection and noise amplification. Since an integrator derives steady state following error to zero, therefore a PI compensator is preferably used rather than a P compensator. The P term may be replaced with a low pass filter for particularly noisy feedback signals. This low pass Plus integral controller is referred to as an LI compensator.
The block diagram of the feed forward, LI controller, is shown in simplified form in FIG. 8. The actuator dynamics are relatively insignificant with a transfer function of unity when the time constant of the low pass filter is a factor of three or more greater than the actuator. Thus, G a →1. The sensor dynamics are similarly insignificant for the same reasons, since noise at its resonate frequency must be filtered.
As a result, H s →1. The kinematic function (differential feed adjustment mechanism, g(u)→g 0 ') is linearized. With the sewing speed having constant (V 0 ), the sewing machine can be expressed as shown in FIG. 8, with the closed loop transfer function as shown in FIG. 9.
The gain K is determined from the transfer function for a required low pass filter time constant τ L , and a desired damping ration ξ. The root locus method for graphically representing pole movement in the complex plane is useful for visualizing the algebra. The basic rule requires open-loop poles to move towards open-loop zeroes as K changes from zero to infinity. Excess poles move toward radially spaced asymptotes The corresponding root locus diagram is show in FIG. 10.
A reasonable upper limit on gain K is obtained by placing complex poles at the optimal damping ratio ξ=0.707, represented as 45° lines. Critically damped poles, ξ=1.0 set a reasonable lower limit on K. The single pole is interpreted as the decay following error τ e , while the pole pair indicates the dynamic response system τ s . Approximate algebraic relationships between system parameters and pole locations are given below. For τ I >>τ L : ##EQU4##
Exact relationships between system parameters and pole locations are given as (for ##EQU5##
The above-described feed forward LI controller was implemented on the system 10 of FIG. 1. As mentioned, the LI controller measures the interaction between the sewing machine and the fabric being sewn and adjusts the feed mechanism such that the desired output is obtained.
In operation, an exemplary easing profile was used in the form shown in FIGS. 11A, 11B and 11C. The profile is entered into the controller 70 by specifying the desired offsets at certain locations along the desired seam. For this exemplary seam, the seam is to be sewn flat (no easing) for the first 4.5 inches, it is to have -0.25 inch offset by the time it has sewn 16 inches and finally, it is to have a -0.125 inch offset when it finishes the seam at 19 inches. This easing profile is similar to that of the inseam of a tailored sleeve.
The next item to be entered to controller 70 is the feed forward gain for the material about to be sewn. Since the ability to ease is different for materials, the feed forward gain is used to fine tune the controller for the specified material being used. The appropriate value for the feed forward gain for a particular material can be experimentally determined by averaging two test runs. Generally, this value related to the material's stiffness.
After entering the easing profile and the feed forward gain, the trailing edge of each ply of cloth is clamped to its tracer or mouse, and the leading edge is placed under the presser foot. The sewing machine's foot pedal is then depressed and the seam is sewn. During sewing, the controller controls the feed mechanism to produce the desired easing output.
FIG. 12 shows a plot of the desired offset and measured offset while sewing the seam profile set forth in FIGS. 11B and 11C. The material sewn was a worsted wool and the sewing speed was 4000 stitches/min. at 10 stitches/inch (thus, taking about 3 seconds to sew the seam). This plot shows that the feed forward LI controller is able to follow the desired input. The plot also shows that the measured offset signal is very noisy.
There are several sources of noise in the measurement of the trailing edge of the plies. The main contributors are cable deflection and cloth deflection. In the system 10, the encoders that measure the position of the mice 18 and 20 are connected to the mice by rubber coated flexible cables 60 and 62. The intermittent feed of the sewing machine creates vibrational waves in these cables. These waves in the cable give erroneous readings as to the location of the mice. To some extent, these vibrational waves can be filtered out in the controller, but additional filtering (filtering over a large number of samples) slows the response of the system. Generally, reducing the waves in the cable cannot be accomplished by putting the cables in tension since any tension on the cables creates elongation in the cloth (another source of measurement error) and changes the characteristics of the way system 10 eases. In the present embodiment, to reduce tension in the cable and to control the unravelling of the cables, the torque motors are controlled under a simple velocity control.
Since each material feeds slightly differently under feed dogs, the feed forward gain for the controller is adjusted for each type of material run through the system. To make the system more adjustable to different material properties, an adaptive controller may be used.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristic thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which comes within the meaning and rage of equivalency of the claims are therefore intended to be embraced therein.
|
The invention includes in one form a sewing machine, two trackers (mice) to track the ends of material-to-be-joined, and a controller for controlling stitch formation to achieve precise control of the material position, permitting desired easing (positive or negative). A long table is preferably used with a separation plate so that the two panels-to-be-joined can be laid out flat and separated during sewing. The mice slide in tracks so they will move in a straight line. The mice are adapted so that tension can be maintained and that the mice can be pulled back when the seam is done. Optical encoders are used so that the position of the mice, and thus endpoints of the panels, can accurately be determined. The sewing machine has an attachment that provides differential feed of the two plies in response to the desired and actual position of the stitches.
| 3
|
FIELD OF THE INVENTION
[0001] This invention relates generally to cellulose-based blanks and containers and more specifically, to wood cellulose-based blanks and containers used for storing and displaying goods.
BACKGROUND
[0002] Containers having multiple thickness corner assemblies are useful where increased container integrity is desired. However, a standard practice employed with using containers with multiple thickness corner assemblies is to adhere all the relative panels together with glue or other type adhesive. In order to erect a container with all relative panels adhered together either large numbers of people hand setting the container, or large box equipment is necessary. Both of these add significant costs.
[0003] What is needed is a method for erecting and the subsequent container that is simple to erect, cost effective and maintains desired container integrity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Various embodiments of the present invention are described in detail below with reference to the following drawings.
[0005] FIG. 1 is a plan view of a single piece of container plank formed in accordance with an aspect of the present invention;
[0006] FIG. 2 is a perspective view of a partially assembled container assembly according to an aspect of the present invention;
[0007] FIG. 3 is another perspective view of a partially assembled container assembly according to yet an another aspect of the present invention;
[0008] FIG. 4 is still further another perspective view of a partially assembled container assembly according to an aspect of the present invention;
[0009] FIG. 5 is still further another perspective view of a partially assembled container assembly according to an aspect of the present invention;
[0010] FIG. 6 is still further another perspective view of a partially assembled container assembly according to an aspect of the present invention; and,
[0011] FIG. 7 is still further another perspective view of a partially assembled container assembly according to an aspect of the present invention.
DETAILED DESCRIPTION
[0012] The present invention provides a blank and resulting container for holding any variety of goods by way of overview and with references to FIGS. 1 through 7 . An embodiment of the present invention includes a single piece blank 20 of foldable material arranged to form a container 50 . Specific details of the blank 20 in container 50 are described with more particularity below.
[0013] FIG. 1 depicts a blank 20 used to form the container 50 . The blank 20 is preferably constructed from a single piece of formable material such as, without limitation, sheets of cellulose-based materials formed from cellulose materials such as wood pulp, straw, cotton, bagasse or the like. Cellulose-based materials used in this present invention come in many forms such as fiberboard, containerboard, corrugated containerboard and paperboard. The various forms may also be constructed in single wall, double wall, or triple wall configuration. The blank 20 is cut and scored, perforated or otherwise formed to include a plurality of panels that when assembled form container 50 . In all FIGURES, like numbers indicate like parts. Additionally, cut lines are shown as solid lines, score lines as dashed lines, and lines of perforation as broken lines.
[0014] With respect to FIG. 1 , the blank 20 includes a bottom panel 22 , opposed side panels 24 and opposed end panels 26 . The bottom panel 22 is generally rectangular in shape and is connected with the side panels along a fold line 23 . The bottom panel 22 is connected with end panels 26 along a fold line 25 . As depicted in the FIGURE, fold line 23 is substantially perpendicular to fold line 25 . The intersection of the respective fold lines 23 and 25 substantially define the corner of the bottom panel 22 and subsequent container 50 .
[0015] Attached to the side panel 24 , opposite the bottom panel 22 , is a top panel 28 . Top panel 28 is attached to side panel 24 along a fold line 27 . The length of the top panel 28 measured along fold line 27 is substantially equal to the length of the side panel 24 measured along the same fold line. The width of the top panel 28 , measure in a direction perpendicular to fold line 27 , in a direction away from side panel 24 , is about ½ the width of the bottom panel 22 measured along fold line 25 .
[0016] Top panel 28 includes a top panel flap 30 which is connected to top panel 28 along fold line 29 . Fold line 29 is lies substantially perpendicular to fold lines 27 and 23 . The length of the top panel flap 30 when measured perpendicularly from fold line 29 and in a direction away from the top panel 28 is substantially equal to the width of side panel 26 measured along fold line 33 .
[0017] End panel 26 includes a corner assembly that when erected into a container, form a unique corner configuration. The corner assembly generally includes a first corner assembly panel 36 attached with the end panel 36 along a fold line 33 . Fold line 33 is substantially parallel to fold line 23 and is substantially formed in the same plane. Connected with the first corner assembly panel 36 opposite the end panel 26 is a second corner assembly panel 38 . The second corner assembly panel is connected to the first corner assembly panel 36 along a fold line 35 . Connected with the second corner assembly panel 38 is a third corner assembly panel 40 . Said third corner assembly panel 40 is connected to second corner assembly panel 38 along a fold line 37 . Fold lines 33 , 35 and 37 are substantially parallel to one another.
[0018] As formed, the first corner assembly panel 36 , second corner assembly panel 38 , and third corner assembly panel 40 lie substantially adjacent to side panel 24 and portions of top panel 28 and top panel flap 30 . In an embodiment, the collective widths of the panels making up the corner assembly ( 36 , 38 , and 40 ) measured along cut line 43 are greater than or equal to the length of the side panel measured along fold line 23 . However, it will be appreciated that the collective widths could also be less than the length of the side panel measured along fold line 23 .
[0019] In order to further illustrate the various aspects of the embodiments, FIGS. 2 through 7 show the blank 20 being erected into container 50 .
[0020] With specific reference to FIGS. 2 and 3 , the assembly of the container 50 is initiated by folding the first corner assembly panel 36 , second corner assembly panel 38 , and third corner assembly panel 40 upwardly approximately 90 degrees on fold line 33 . The end panel 26 may also be folded upwardly approximately 90 degrees along a fold line 25 . As best seen in FIG. 2 , this forms a substantially U-shaped structure including the end panels 26 and the opposed corner assembly panels. Also, this places the respective corner assembly panels that are attached to the opposed end panels 26 in a substantially juxtaposed relationship to one another. The next step in the box erection process is to fold side panels 24 upwardly approximately 90 degrees so that side panel 24 is juxtaposed to the various corner assembly panels, as best seen in FIG. 3 .
[0021] With specific reference to FIGS. 4 and 5 , the assembly of the L-corners and end wall top panel support is depicted. Specifically, the second corner assembly panel 38 and third corner assembly panel 40 are folded inwardly approximately 180 degrees along fold line 35 . As such, fold line 37 is substantially in the corner of the container 50 , the third corner assembly panel 40 is adjacent to the end panel 26 , and the second corner assembly panel is substantially adjacent to the first corner assembly panel. At this time, the free third corner assembly panel 40 may be engaged into the end panel slot 42 to lock the L-corner panels together, as best seen in FIG. 5 .
[0022] With specific reference to FIGS. 6 through 7 , the top panel flaps 30 may then be folded inwardly approximately 90 degrees along fold line 29 . Top panel 28 may then be folded inwardly approximately 90 degrees along fold line 27 . In this manner the container may be formed closing the lids, wherein the top panels 28 receive additional support from the top panel flaps 30 extending between the top panel 28 and the bearing surface created by top panel support cutout 46 .
[0023] It will be appreciated by those skilled in the art that the relationship of the top panel flap 30 , top panel support cutout 46 and end panel 26 aid to the stability of the container 50 . Specifically,
[0024] FIG. 7 depict the container 50 that results from the assembly of blank 20 . As can be seen in this FIGURE, the container 50 includes reinforced multi-panel corner arrangements. Specifically, all four corners receive added rigidity thanks to the overlapping relationship of the various side corner assembly panels and their respective side wall 24 or end wall 26 . The arrangement of the corner assembly panels help the container 50 control relative motion of the side panels 24 and end panels 26 . The corner assembly panels also provide a significant increase in the container's stacking strength. Further, top panel 28 provides a stacking or bearing surface for successive containers 50 to be stacked vertically on top of one another (not shown).
[0025] One of the many unique features of this embodiment is the extremely limited use of adhesive. Specifically, with reference to all FIGURES, the only adhesive used in the formation and use of container 50 is located between side panel 24 and the first corner assembly panel 36 . The specific location where the adhesive 47 is placed between the respective panels will be known to those skilled in the art and it its location shown in FIG. 1 is strictly exemplary. However, it will be appreciated that the location and amount of adhesive 47 used will be sufficient to ensure container integrity. The other panels are essentially free from adhesive or the like. They may be hand set and are generally friction fit.
[0026] A unique benefit is that the forming of container 50 may be done much more efficiently than before. Specifically, if box formers are to be used in erecting the container 50 , a box former having a relatively small footprint may be use. Suitable, non-limiting examples of such a box formers are the vertical box formers manufactured by either FWF, Inc. or W.E. Plemons, Inc. each of these companies manufacture relatively simple box formers having footprints around 4′×6′. This footprint is significantly smaller than box formers typically used to erect fully glued containers. If the container 50 is to be fully hand set rather either partially or fully machine formed, the number of people required to erect the container is greatly reduced.
[0027] The simple adhesive arrangement of the disclosed container 50 and the minimal assembly space requirement provides a variety of efficiencies for a user. As discussed above, the actual floor space needed for either machine formation or hand formation is reduced by the unique and limited adhesive 47 application. This reduced floor space usage is a cost savings. Also, smaller entities that formerly could not justify the expense of larger box erecting equipment may now utilize less voluminous box erecting equipment and produce a container 50 having desirable structural qualities.
[0028] The container 50 as shown is simple to manufacture, easy to assemble and may be a design of considerable usage in club stores or bulk stores where products are sold in large quantities on the open floor. The container 50 may be erected by standard box erecting equipment (not shown) or else is may be hand-set and tape/glued when needed. However, this design is also useful in any variety of retail or wholesale environments.
[0029] While various embodiments of this invention have been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of this invention. Accordingly, the scope of the invention is not limited by the disclosure of the various embodiments. Instead, the invention should be determined entirely by references to the claims that follow.
|
The embodiments of the present invention provide a blank foldable material that may be configured to form a container. When formed, the container is self-locking and includes top panel assemblies that form additional bearing surfaces. The blank is configured to form a container that includes corners having multiple thicknesses. However, despite the multiple thickness of the corner assemblies, the panels are only adhered in one location per corner. The single adhesion/corner arrangement provides a multi-wall corner arrangement that is strong, yet has flexible applications. The single adhesive/corner adds vertical stacking strength and lateral stability between the panels. The unique approach of only adhering at one place per corner is a space and cost saving improvement that maintains a container integrity and usefulness.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from Provisional Patent Application No. 60/688,069 filed Jun. 7, 2005, and entitled “SUPER CELL UNIVERSALLY INTERCHANGEABLE WORKOUT STATION”.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to apparatus, including a kit of assembly parts, which enables the construction of one or more exercise workout stations, as defined and assembled by a user.
[0003] There are a great many individualized pieces of fitness and exercise equipment commercially available at the present time. These pieces of equipment are normally single-purpose by design, but in some instances a plurality of such pieces of equipment are combined to form multi-purpose exercise apparatus.
[0004] Such “multi-station” machines are comprised of a series of weight stacks, seats, cables, benches, bars, pulleys and the like, all configured into a preset, fixed arrangement. Although these multi-station machines offer a variety of exercise devices and permit multiple users to work out at the same time, they lack the versatility of being integrated with almost any other type of exercise equipment. Moreover, once configured at the factory, these multi-station machines are difficult, if not impossible to reconfigure, rearrange and/or expand into different or larger multi-stations.
SUMMARY OF THE INVENTION
[0005] A principle object of the present invention is to provide apparatus which is capable of being assembled and configured into any number of strength-training, exercise systems. More particularly, the invention concerns apparatus which can be formed into one or more readily customizable, and universally interchangeable, workout stations, which can either stand on their own or be attached to existing fixtures, such as previously purchased stand-alone exercise equipment or the fixtures, walls, etc. of an exercise room.
[0006] Still another object of the present invention is to provide user-defined exercise apparatus which may be configured into a multi-user workout station, as described above, which conveniently allows the attachment of a plurality of exercise devices of the same or different type while, in addition, can be used as a storage center for items normally found at a fitness center such as bands, weights, balls, bars, barbells, etc.
[0007] It is a still further object of the present invention to provide apparatus which may be configured into a user defined workout station and then later either reconfigured into another workout station or expanded into a larger multi-user station.
[0008] These objects, as well as further objects which will become apparent from the discussion that follows, are achieved, in accordance with the present invention, by providing a kit of parts which may be assembled and erected into exercise apparatus of various configurations, as desired and defined by the user.
[0009] As a minimum, this kit comprises the following elements:
[0010] (1) a plurality of frames adapted for substantially upright installation, each frame comprising two substantially identical elongate vertical members of a first prescribed length, each having two ends, which are connected together in parallel and in spaced-apart relationship by a horizontal crossbar of a second prescribed length adjacent each end, each of said vertical members having a plurality of points of attachment along its length; and
[0011] (2) at least one elongate horizontal member of a third prescribed length, each horizontal member adapted for connecting a separate one of the vertical members of a first frame with a corresponding one of the vertical members of a second frame, respectively, adjacent one of the upper and lower ends of the vertical members, thereby to form a supporting cell of frames.
[0012] The frames, which as a minimum have two vertical members connected in parallel relationship by the two crossbars, preferably comprise a large number of crossbars spaced equidistantly along the length of the vertical members, like rungs of a ladder to form a ladder-like structure.
[0013] Preferably also, the kit comprises a plurality of such horizontal members, enabling the user to assemble and connect two or more of the frames into various self-standing structures to form the supporting cell of frames. For example, two frames and two horizontal members may be connected in a Z-shaped configuration, with one horizontal member interconnecting two vertical members (one in each frame) near the top, and the other horizontal member interconnecting the same two vertical members near the bottom.
[0014] In another configuration, four horizontal members may connect two frames in a box-like or rectangular configuration to form a self-supporting cell.
[0015] In still further configurations, three or more frames may be interconnected to form a self-standing cell in the shape of a triangle, a pentagon, an octagon, etc.
[0016] The vertical and horizontal members included in the kit are all of a prescribed, standardized length. Advantageously, and in accordance with a further feature of the present invention, additional horizontal members may be provided that are all in a different, standardized length (either longer or shorter than the above-noted horizontal members). These additional horizontal members may be used for interconnecting frames or for connecting frames to a building structure, such as a wall. They may also be used to interconnect two or more self-supporting cells to form a larger, multi-user station.
[0017] As noted above, the vertical members in each frame have a plurality of points of attachment along their length. These facilitate the removable attachment of any one of a number of exercise devices to form a multi-user fitness workout station of virtually any desired design. In addition, once configured and assembled into a cell, the vertical members provide support for one or more storage devices, attached inside and/or outside the cell, permitting convenient storage of such items as bands, balls, bars, weights, etc.
[0018] The kit of standardized parts, according to the invention, offers a number of advantages over the exercise apparatus of the prior art.
[0019] 1. They eliminate the need, required for many items, to be attachable to a reinforced wall or other solid building surface. Such building structures are difficult to utilize for exercise equipment since drywall walls are inadequate for the support of such equipment and wall struts are not readily found.
[0020] 2. By replacing individual exercise machines or dedicated multi-user workstations with self-standing supporting cells, to which a large variety of exercise devices may be attached, the floor space normally required for a fitness center may be reduced to a relatively modest “footprint” of one, or just a few, supporting cells.
[0021] 3. The exercise apparatus according to the invention is easily transportable. The supporting cell or cells may be easily disassembled and transported, together with their attachable exercise devices, to another location. The apparatus is ideal for military use, for example, since it can be transported and assembled in a tent.
[0022] 4. The exercise apparatus according to the invention is substantially less costly to manufacture, transport and install than the many individual exercise units or multi-station units known in the art. The single framework forming a supporting cell, according to the present invention, shares common parts onto itself, it allows the sharing of common parts, such as bars, weights, bands, etc., among the various exercise devices and, most importantly, it forms a common support structure for the attachment of one or more or a large variety of exercise devices. There is a substantial cost saving since these various exercise devices need not each have its own separate support structure.
[0023] 5. Last but not least, the exercise apparatus according to the invention eliminates most of the barriers disabled users face in using other machines which require frames and standing supports to hold them sturdy. These known structures almost always interfere with someone in a wheelchair. By offering a user-defined supporting framework that allows for virtually unlimited interchangeability of attachments, the invention allows users in wheelchairs to custom design their own equipment so that they can take advantage of the many fitness exercises that able-bodied persons also enjoy.
[0024] For a full understanding of the present invention, reference should now be made to the following detailed description of the preferred embodiments of the invention as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a perspective view of a typical group of standardized parts which may form an assembly kit, according to the present invention, for erecting a supporting cell for exercise apparatus.
[0026] FIG. 2A is a perspective view of two frames connected in a Z-shaped configuration to form a supporting cell.
[0027] FIG. 2B is a perspective view of a single frame attached to a wall.
[0028] FIG. 3 is a perspective view of two frames connected in a rectangular configuration to form a supporting cell.
[0029] FIG. 4 is a perspective view of three frames connected in a pentagonal configuration to form a supporting cell.
[0030] FIG. 5 is a perspective view of two supporting cells of the type shown in FIG. 4 connected together to form a multiple-cell configuration.
[0031] FIGS. 6, 7 and 8 are perspective, side and top views, respectively, of the rectangular supporting cell of FIG. 3 with various exercise devices attached thereto.
[0032] FIGS. 9 a and 9 b are perspective and cross-sectional views, respectively, illustrating the preferred embodiment of the mode of attachment of an exercise device on a supporting cell.
[0033] FIG. 10 is a perspective view of an alternative embodiment of the mode of attachment of an exercise device on a supporting cell.
[0034] FIG. 11 is a perspective view of another alternative embodiment of the mode of attachment of an exercise device on a supporting cell.
[0035] FIG. 12 is a side view of the supporting cell of FIG. 3 incorporating a cable-operated exercise device and having another exercise device, called a “Kaplan Cell”, arranged in front of it.
[0036] FIG. 13 is a side view of the supporting cell of FIG. 12 with the cable-operated exercise device incorporated therein.
[0037] FIG. 14 is a perspective view of the supporting cell of FIGS. 12 and 13 .
[0038] FIG. 15 is a detailed perspective view of the Kaplan Cell shown in FIG. 12 .
[0039] FIG. 16 is a perspective view of the supporting cell of FIG. 3 , similar to that of FIGS. 6-8 , with various other exercise and storage devices attached thereto.
[0040] FIG. 17 is a perspective view of two supporting cells of the type shown in FIG. 3 , connected together side by side and supporting a large variety of exercise and storage devices.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] The preferred embodiments of the present invention will now be described with reference to FIGS. 1-17 of the drawings. Identical elements in the various figures are designated with the same reference numerals.
[0042] FIG. 1 illustrates an assembly kit of standardized parts which can be used to erect exercise apparatus in any one of a number of different configurations, as will be explained below. In this particular instance, the kit includes two “frames” 10 a and 10 b each comprising two substantially identical vertical members 12 and 14 which are connected together at each end by round crossbars 16 . Preferably, the frames 10 are provided with a greater number of these crossbars, interconnecting the vertical members, which are spaced equidistantly along the lengths of the vertical members like rungs of a ladder.
[0043] The vertical members 12 and 14 are each provided with holes, slots, hooks or the like equidistantly spaced along opposite sides, which serve as points of attachment for exercise devices, storage devices or other useful devices or things, when the respective frames are assembled in a workout space.
[0044] Advantageously, the frames 10 are also provided with adjustable feet 18 at the bottom of each vertical member, in the manner known in the art, permitting level adjustment of the frames on an uneven, or slanted floor.
[0045] Included in the kit are a plurality of bars 20 a , 20 b , 22 a , 22 b , 24 a and 24 b , in prescribed, standardized lengths for connecting the frames 10 together to form a self-standing “supporting cell” of frames for a workout station. The bars can also be used to connect a single frame to a building fixture or structure, such as a wall, or to connect multiple supporting cells together.
[0046] FIG. 2A illustrates how two frames 10 a and 10 b may be easily connected in a Z-shaped configuration using one of the horizontal bars 20 a . The horizontal bar 20 a is attached to the tops of two vertical members 14 and 12 , respectively, of the frames 10 a and 10 b by bolts 21 which pass through the bar 20 a and are screwed into threaded holes in the vertical members.
[0047] FIG. 2B shows how a single frame 10 , comprising vertical members 12 and 14 , may be affixed to a wall 15 by means of short horizontal bars 22 a and 22 b , attached at the tops of the vertical members 12 and 14 by bolts 21 .
[0048] FIG. 3 illustrates a supporting cell 26 formed of kit parts 10 a , 10 b , 20 a , 20 b , 20 c and 20 d , connected together in a box-like configuration. The bars 20 a , 20 b , 20 c and 20 d are attached to the upper and lower extremities of the frames 10 a and 10 b , respectively, by means of bolts 21 which pass through the vertical members and are screwed into threaded holes at the ends of the bars 20 .
[0049] FIG. 4 illustrates how three frames 10 a , 10 b and 10 c can be joined together by horizontal bars 20 a , 20 b and 20 c to form a pentagonal shaped supporting cell 28 . As in the case of the configuration in FIG. 2 , the horizontal bars 20 are bolted to the tops of the vertical members 12 and 14 of each frame.
[0050] FIG. 5 illustrates how two supporting cells, for example of the type 28 shown in FIG. 4 , may be connected together by means of the horizontal bars 24 a and 24 b to form an expanded, double supporting cell.
[0051] As may be seen, a kit of parts of the type shown in FIG. 1 may be used to design and construct supporting cells of various sizes and shapes to form a basic unit for the attachment of one or more exercise devices. A particular example, illustrating the use of the supporting cell 26 of FIG. 3 to create customized exercise apparatus, will now be described with reference to FIGS. 6-9 .
[0052] FIGS. 6-8 illustrate a supporting cell of the type 26 shown in FIG. 3 to which are attached a number of exercise devices. Attachment is by means of bolts which are screwed into threaded holes at the tops of the vertical frame members and by quick connections, which are illustrated in FIGS. 9 a and 9 b , that make use of the holes, or other attachment means, in the sides of each vertical member.
[0053] Shown in FIG. 6 are a horizontal ladder 30 , attached to the tops of the frames 10 a and 10 b by bolts; a horizontal bar 32 , also attached by bolts to the tops of the frames; a chin-up station or barbell holder 34 ; a combination squat rack/bench press/horizontal push-up station 36 and a so-called “dipping station” 38 comprised of two separately connected bars 38 a and 38 b.
[0054] The horizontal bar 32 may be used to support a hanging punching bag, boxing “speed bag” or other similar accessory.
[0055] Alternatively, or in addition, various other exercise devices may be removably attached to the supporting cell 26 . As noted above in connection with FIG. 5 , two or more supporting cells may be connected together to provide additional space for a larger variety of exercise devices.
[0056] Set forth below is a list of the common exercise devices which may be removably attached to one or more supporting cells. By providing a common structure for supporting these devices, the devices need not each have their own supporting structure, resulting in a substantial reduction in cost.
( 1 ) a bench press; ( 2 ) a barbell rack; ( 3 ) a weight rack; ( 4 ) a pair of balance beams; ( 5 ) a squat rack; ( 6 ) a calf block; ( 7 ) a leg rest; ( 8 ) a dip station; ( 9 ) a punching bag; ( 10 ) a horizontal ladder; ( 11 ) a horizontal chin-up bar; ( 12 ) a horizontal push-up bar; ( 13 ) a foot stand; ( 14 ) a connection device for elastic bands; ( 15 ) a cable pull device connected to a resistance means; and ( 16 ) a sliding bench.
[0073] Tipping of the supporting cell, and thus the entire structure, during use of the exercise devices is prevented by the addition of horizontal stabilizer bars 39 a and 39 b . These bars may be bolted directly to the frames 10 a and 10 b or to the interconnecting horizontal members 20 c and 20 d as shown.
[0074] FIGS. 10 and 11 illustrate alternative arrangements for removably attaching exercise devices to the vertical members 10 a and 10 b of a frame. In FIG. 10 the vertical members 10 are provided with spaced-apart slots; in FIG. 11 , the vertical members 10 are provided with spaced-apart hooks for hanging the various devices.
[0075] FIGS. 12-14 show still another use of the supporting cell 26 of FIG. 3 . In this case, the supporting cell is provided with two exercise devices, namely; (1) a cable-operated exercise device 40 for pulling a handle against an adjustable resistance, and (2) a so-called “Kaplan Cell” 50 with a large stability ball 51 . As is best illustrated in FIG. 14 , the cable-operated device 40 comprises two vertical members 41 a and 41 b attached top and bottom to the horizontal members 20 a and 20 c . Short crossbars 43 a , 43 b , 43 c and 43 d serve to interconnect the vertical members 41 a and 41 b to the horizontal members 20 a and 20 c , forming a U-shaped structure within the supporting cell. The crossbars 43 support two vertical rods 42 a and 42 b which, in turn, serve as rails for a moveable carriage 44 . This carriage is connected to the distal ends of two cables 47 a and 47 b (shown in dashed lines in FIG. 13 ) that may be pulled by a user to raise the carriage 44 upward against the force of the resistance. The means of resistance may be a weight stack (not shown), from which the user may select one or more weights, one or more elastic bands (shown in FIG. 14 as springs 49 a and 49 b attached to a hook rack) and one or more hydraulic or pneumatic dampers (not shown), or a combination of these.
[0076] The Kaplan Cell 50 is shown in detail in FIG. 15 . This Cell, which may be attached to the base of the supporting cell 26 , comprises two foot pads 52 a and 52 b as well as two foot bolsters 54 a and 54 b , for use when the person sits either on an accompanying seat or is supported by the ball 51 . Cable extensions 47 c and 47 d may be clipped onto the proximal ends of the cables 47 a and 47 b , respectively, to permit the user to exercise in the sitting position by pulling the cables in a “rowing” motion.
[0077] FIG. 16 illustrates the rectangular supporting cell 26 with a further variety of exercise devices attached thereto. These devices include a heavy punching bag 70 , a boxing “speed ball” 72 , a dip station 74 and a squat rack 76 . In addition, the supporting cell serves as a storage unit 78 for various items such as medicine balls, weights, elastic bands and the like.
[0078] FIG. 17 illustrates how an arrangement of the type shown in FIG. 16 may be expanded to include still further exercise devices, as desired. In this case, two supporting cells 26 are connected together by horizontal bars to accommodate the addition of a Kaplan Cell 50 and also a second type of cable-operated resistance device 80 as well as a sliding bench 82 . The cable-operated device 80 , which allows a user to pull one or both of two cables from any one of number of points along an arc, is fully disclosed in my co-pending U.S. patent application Ser. No. 11/408,213, filed Apr. 20, 2006, which application is incorporated herein by reference.
[0079] There has thus been shown and described a novel user-defined exercise apparatus which fulfills all the objects and advantages sought therefor. Many changes, modifications, variations and other uses and applications of the subject invention will, however, become apparent to those skilled in the art after considering this specification and the accompanying drawings which disclose the preferred embodiments thereof. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention, which is to be limited only by the claims which follow.
|
A kit of parts is provided for assembly into exercise apparatus of various configurations, as desired and defined by the user. The apparatus, when configured to form a supporting cell, conveniently allows the attachment of a plurality of exercise devices of the same or different type while, in addition, can be used as a storage center for items normally found at a fitness center such as bands, weights, balls, bars, barbells, etc.
| 0
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The contents of this application are related to U.S. design patent applications having Ser. Nos. 29/182,901, 29/182,878, and 29/182,914, filed on Jun. 2, 2003, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to theft deterrent security tags in general, and in particular to an integrated security tag containing an attaching pin that emanates from the tag body for use in electronic article surveillance (EAS) tags for theft deterrence.
BACKGROUND OF THE INVENTION:
[0003] Various types of electronic article surveillance (EAS) systems are known having the common feature of employing a marker or tag which is affixed to an article to be protected against theft from a controlled area, such as merchandise in a store. When a legitimate purchase of the article is made, the marker can either be removed from the article, or converted from an activated state to a deactivated state. Such systems employ a detection arrangement, commonly placed at all exits of a store, and if an activated marker passes through the detection system, it is detected by the detection system and an alarm is triggered.
[0004] Such electronic detection arrangements, as used in the present invention, are well known in the art and are more clearly discussed in my co-pending U.S. patent application Ser. No. 10/410,486, titled “Article Surveillance Tag Having a Metal Clip,” filed on Apr. 8, 2003, which is incorporated herein by reference. In addition, the locking mechanism and removal tool, as used in the instant invention, are also well known in the art and are disclosed in U.S. Pat. No. 3,588,280 to Martin A. J. Marens and U.S. Pat. No. 3,911,534 to Henry J. Martens et al. which disclosures are incorporated herein by reference for a complete understanding of the locking device employed in the present invention. A discussion of the inventions in the field, known to the inventor, and their differences from the present invention is provided below.
[0005] U.S. Pat. Nos. 3,911,534 and 3,974,581 to Henry J. Martens et al. disclose a security tag having the pin contained on a first strip that is attached by a hinge to a second strip that has the locking component thereon. The hinged attachment may lead to the bending of the pin when contacting the locking component because of the predetermined arc that it must travel as a result of the hinged arrangement. Furthermore, the hinged arrangement allows the pin to protrude vertically when the device has fallen to the floor and may lead to injury. The '534 and '581 patents also disclose a pin soldered to a chain at one end and the other end of the chain riveted to the tag cover. The riveting of the chain on the outside of the tag body may subject the tag easy defeat by unscrupulous individuals. Furthermore, the pin thereof will protrude vertically when the device has fallen to the floor and may lead to injury.
[0006] U.S. Pat. No. 3,932,918 to Paskert discloses a releasably attachable clip for attachment to certain cloth articles, wherein the pin component is incorporated into the tag. However, the pin once again is held in a substantially hinged relation to the locking component and may lead to bending of the pin as a result of the arc which must be traveled in order to engage the locking component. Furthermore, the '918 patent may only be used with articles made of cloth and cannot engage solid components as disclosed in the instant invention.
[0007] U.S. Pat. No. 3,942,829 to Humble et al. discloses a security tag having the pin contained on a first strip that is attached by a hinge to a second strip that has the locking component thereon. The hinged attachment may lead to the bending of the pin when contacting the locking component because of the predetermined arc that it must travel as a result of the hinged arrangement. In addition, the hinged arrangement allows the pin to protrude vertically when the device has fallen to the floor and may lead to injury. Furthermore, the '829 patent may only be used with articles made of cloth and cannot engage solid components as disclosed in the instant invention.
[0008] U.S. Pat. No. 6,535,130 to Nguyen et al. discloses a complex electronic tag having visual and audible alarm systems incorporated into the tag body itself. The tag also incorporates a lanyard that is made of an electrical circuit wire that will cause an audible or visual alarm in the tag body to be activated should the lanyard be cut. The Nguyen device, however, uses a traditional independent pin having a head to attach the lanyard to an article, thereby possibly leading to work place injuries when the pin is dropped on the floor. Furthermore, the electrical components incorporated into each tag make the manufacture and use thereof cost prohibitive.
[0009] The prior art does not address the need for an integrated EAS tag that is difficult to defeat and easy to use. In addition, the prior art fails to provide a theft deterrent tag assembly that incorporates the pin, a lanyard and the tag body into one unit. Therefore, there remains a long standing and continuing need for an advance in the art of EAS and theft deterrent tags that makes the tags more difficult to defeat, simpler in both design and use, more economical and efficient in their construction and use, and provide a more secure engagement of the article.
SUMMARY OF THE INVENTION
[0010] Accordingly, it is a general object of the present invention to overcome the disadvantages of the prior art.
[0011] Therefore, it is a primary objective of the invention to provide an EAS tag wherein the tag body and the pin are an integrated unit.
[0012] It is another objective of the invention to provide a cost-efficient EAS tag.
[0013] It is another objective of the invention to provide an EAS tag that is durable.
[0014] It is a further objective of the invention to provide an EAS tag that is detachable when used with an authorized detaching unit.
[0015] It is a further objective of the invention to provide an EAS tag that provides an integrated pin to reduce the chances of injury to persons stepping on the pin, as is commonly a problem with the pins utilized in the prior art.
[0016] It is still a further objective of the invention to provide a theft deterrent device that can be quickly and easily secured to an article made of varying materials to prevent the unauthorized removal of the article.
[0017] It is yet a further object of the invention to provide a rugged theft deterrent unit to permit the repeated reuse thereof.
[0018] In keeping with the principles of the present invention, a unique EAS theft deterrent tag is disclosed wherein the pin element is integrated into the tag body via an elongated element. In integrating the pin component with the tag body, labor time and costs are reduced when removing the tag from an article being protected thereby because separate bins are not required for storing the tag body and the pin component until they are reused. In addition, labor time and costs during attachment of the tag body to an article are also reduced because the pin component is integrated therewith and a separate search for a corresponding pin is eliminated. In addition, the risk of work place injury is reduced because when the tag body falls on the floor, the pin also lays flat on the floor and should not penetrate the foot of an employee stepping thereon. Conversely, the pins illustrated in the prior art have a head on which the pin will rest and leave the shaft thereof in a vertical plane thereby increasing the risk of foot injuries.
[0019] Such stated objects and advantages of the invention are only examples and should not be construed as limiting the present invention. These and other objects, features, aspects, and advantages of the invention herein will become more apparent from the following detailed description of the embodiments of the invention when taken in conjunction with the accompanying drawings and the claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] It is to be understood that the drawings are to be used for the purposes of illustration only and not as a definition of the limits of the invention. In the drawings, wherein similar reference characters denote similar elements throughout the several views:
[0021] FIG. 1 is a top perspective view of the tag of the instant invention.
[0022] FIG. 2 is a side elevational view of the tag of the instant invention.
[0023] FIG. 3 is a perspective view of the tag of the instant invention showing an alternate preferred embodiment.
[0024] FIG. 4 is a cross sectional view of the tag of the instant invention taken along line 4 - 4 of FIG. 1 .
[0025] FIG. 5 is a top perspective view of the tag of the instant invention showing an alternate preferred embodiment that does not incorporate electromagnetic components therein.
[0026] FIG. 6 is a cross sectional view of the tag of the instant invention taken along line 6 - 6 of FIG. 5 .
[0027] FIG. 7 is a perspective view of the tag of the instant invention showing an alternate preferred embodiment where the pin is not directly attached to the lanyard.
[0028] FIG. 8 is a perspective view of the tag of the present invention showing an alternate preferred embodiment thereof.
[0029] FIG. 9 is a perspective view of the tag of the present invention showing an alternate preferred embodiment thereof.
DETAILED DESCRIPTION OF THE INVENTION
[0030] Referring now to FIGS. 1 , 2 and 4 , a tag 20 is illustrated having a first half 22 and a second half 24 . First and second halves 22 and 24 are preferably made of a hard or rigid material and are adapted to attach to one another and form a front end 21 and a rear end 23 . A usable rigid or hard material might be a hard plastic such as, for purposes of illustration but not limitation, an injection molded ABS plastic. If a plastic material is used, the mating of a first side wall 26 to a second side wall 28 can be accomplished via an ultrasonic weld or like joining mechanism. However, it is to be understood that other joining methods, such as adhesives, may also be used. When first half 22 and second half 24 are securely joined, first sidewall 26 and second sidewall 28 form a peripheral outer wall of tag 20 . Second half 24 has an apex region 25 that extends therefrom in an opposing direction to first half 22 in a substantially dome shaped manner. The dome shaped apex region 25 forces tag 20 to fall onto its side such that a pin 48 (described hereinafter) is not vertically oriented and prevents injury by accidentally stepping thereon.
[0031] An opening 30 is defined on first half 22 and is axially aligned with apex region 25 . Apex region 25 encloses a locking mechanism 32 . Locking mechanism 32 is not the subject of the instant invention and a detailed description thereof is disclosed in U.S. Pat. Nos. 3,858,280 and 3,911,534 to Martens et al., which is incorporated herein by reference. In addition, first half 22 and second half 24 enclose a resonant tag circuit 34 which is not the subject of the instant invention and a detailed description thereof is disclosed in my U.S. patent application Ser. No. 10/410,486, titled “Article Surveillance Tag Having a Metal Clip,” filed on Apr. 8, 2003, which is incorporated herein by reference. It is to be understood that alternate resonant tag circuitry that is known in the art may also be used with the instant invention. Resonant tag circuit 34 functions with electronic article surveillance systems that are well known in the art to prevent theft and similar unauthorized removal of articles from a controlled area.
[0032] An aperture 36 is defined through tag 20 to allow a lanyard 38 , preferably formed of stainless steel cable, to pass therethrough. Lanyard 38 is flexible and has a first end 40 and a second end 42 . First end 40 is inserted through aperture 36 and an anchor 44 , having a greater diameter than aperture 36 , is attached to first end 40 . Anchor 44 may be formed by crimping a metal element onto first end 40 or by soldering thereon. In addition, anchor 44 may also preferably be formed by crimp splices. Anchor 44 securely maintains lanyard 38 within tag 20 . A reinforcement wall 46 , having a preferably tubular shape, extends inwardly from top half 22 and further defines aperture 36 such that a greater pull force would be required in order to pull lanyard 38 out of tag 20 through aperture 36 . After lanyard 38 has passed through aperture 36 and anchor 44 engaged therein, first half 22 and second half 24 are sonic welded together, thereby enclosing anchor 44 therein.
[0033] Second end 42 of lanyard 38 receives a pin 48 thereon in substantially axial alignment. Pin 48 has a pointed end 50 and a dull end 52 . Grooves 54 extend circumferentially along pin 48 and provide a more secure engagement when pin 48 is received within locking mechanism 32 . Dull end 52 of pin 48 is attached to second end 42 of lanyard 38 by an attaching element 56 . Attaching element 56 may be formed by crimping a metal element around dull end 52 and second end 42 or by soldering a metal element thereon, thereby permanently fixing the attaching element 56 , dull end 52 and second end 42 together. In addition, attaching element 56 may also preferably be formed by crimp splices.
[0034] Now referring to FIG. 3 , an alternate preferred embodiment of tag 20 is disclosed wherein an extension barrier 58 extends outwardly from first half 22 and substantially encircles opening 30 . Extension barrier 58 is substantially tubular and is intended to prevent access to pin 48 when it is inserted within opening 30 and received within locking mechanism 32 .
[0035] Now referring to FIGS. 5 , 6 and 7 , an alternate preferred embodiment of tag 20 is disclosed wherein the resonant tag circuit 34 is removed in order to minimize the size of tag 20 . The alternate preferred embodiment is of compact size and is attachable to small articles, such as sunglasses, in order to provide theft deterrence.
[0036] Now referring to FIG. 8 , an alternate preferred embodiment of tag 20 is disclosed wherein the aperture 36 extends is defined by front end 21 and is perpendicular to the axis of opening 30 . Now referring to FIG. 9 , an alternate preferred embodiment of tag 20 is disclosed wherein the aperture 36 is defined by rear end 23 and is perpendicular to the axis of opening 30 .
[0037] For attachment of tag 20 to articles of clothing, pointed end 50 of pin 48 passes through the article of clothing and is inserted into opening 30 and received within locking mechanism 32 . For delicate fabrics, such as lingerie or silk blouses, the lanyard attaches around a portion of the article and forms a loop around the article when pin 48 is inserted into locking mechanism 32 . Tag 20 may also be used with solid articles, such as baseball bats, wherein a loop is formed by the lanyard around the solid article (i.e. the handle of the baseball bat).
[0038] While the above description contains many specificities, these should not be construed as limitations on the scope of the invention, but rather as an exemplification of one preferred embodiment thereof. Many other variations are possible without departing from the essential spirit of this invention. Accordingly, the scope of the invention should be determined not by the embodiment illustrated, but by the appended claims and their legal equivalents.
|
An integrated theft deterrent tag 20 having a lanyard 38 emanating therefrom. The lanyard 38 having a pin 48 permanently attached thereto and the pin 48 being received within a locking mechanism 32 and enclosing an article to be protected.
| 8
|
BACKGROUND OF THE INVENTION
This invention relates to low tantalum content cobalt-base alloys.
In one of its more specific aspects this invention relates to articles made from such alloys, particularly articles made by casting.
In certain industrial applications, there is a need for alloys which possess high rupture strength and high oxidation resistance at high temperatures. Among such applications are those involved, for example, in the glass fiber industry, where filaments are produced by passing a molten material, for example, glass, through the foraminous walls of a chamber adapted for rotation at high speeds, the chamber being known as a spinner, the filaments being emitted through the apertures of the wall due to the centrifugal action to which the molten material is subjected upon rotation of the spinner. Such spinners are usually operated when spinning glass fibers at temperatures of about 2,050° F. and rotational speeds of about 1,700 RPM. Under these conditions, the alloy of this invention has been found to possess superior stress-rupture and creep properties and superior resistance to the molten glass environment to which it is subjected.
One of the best materials known for use in such applications is that defined and claimed in U.S. Pat. No. 3,933,484 issued Jan. 20, 1976. That alloy contains on a weight basis from about 1.4 to about 6.5 percent tantalum. However, tantalum is very expensive and because significant quantities of tantalum are lost during the preparation of the alloy, amounts greater than the defined amounts must be used in achieving the ultimately desired tantalum content in the final alloy. This invention is directed to the solution of that problem.
STATEMENT OF THE INVENTION
According to this invention there is provided a composition of matter possessing the following approximate composition, the various components of this composition being expressed on a weight percent basis:
______________________________________Element Approximate Composition, Weight %______________________________________Chromium About 25. to about 36.Nickel About 3.5 to about 13.Wolfram About 3. to about 10.5Tantalum About 0 to about 1.2Zirconium About 0.005 to about 0.2Silicon About 0.05 to about 2.Carbon About 0.35 to about 0.95Boron About 0.001 to about 0.1Iron About 0.01 to about 12. -Cobalt Balance______________________________________
In the above composition, the weight ratio of zirconium to boron will be within the range of from about 0.05 to about 35.
The preferred composition of this invention will be approximately as follows, on a weight percent basis:
______________________________________Element Approximate Composition, Weight %______________________________________Chromium About 28.5 to about 33.Nickel About 9.5 to about 11.Wolfram About 5.5 to about 8.Tantalum About 0.8 to about 1.2Zirconium About 0.009 to about 0.025Silicon About 0.25 to about 0.7Carbon About 0.5 to about 0.65Boron About 0.01 to about 0.035Iron About 0.25 to about 0.6Cobalt Balance______________________________________
In the preferred composition, the weight ratio of zirconium to boron will be within the range of from about 0.25 to about 0.9.
The best mode of practicing the invention is represented by the following approximate composition on a weight percent basis:
______________________________________Element Approximate Composition, Weight %______________________________________Chromium About 31.2Nickel About 10.4Wolfram About 6.5Tantalum About 0.8 to 1.0Zirconium About 0.01Silicon About 0.38Carbon About 0.58Boron About 0.03Iron About 0.32Cobalt Balance______________________________________
In the above composition, the weight ratio of zirconium to boron will be about 0.3.
The above compositions are not meant to preclude the presence of impurities which are inherently contained in the principal components previously set forth. However, these impurities should be limited to about 0.1 weight percent aluminum, about 0.1 weight percent titanium, about 0.015 weight percent sulfur and about 0.015 weight percent phosphorous.
Suitable tantalum contents, in weight percent, have also been found to be in the ranges of about 0.8 to about 1.1, and about 0.5 to about 1.2.
Particularly suitable tantalum contents in weight percent have been found to be 0.9, 1.0 and 1.2.
DETAILED DESCRIPTION OF THE INVENTION
The compositions of this invention can be prepared by air melting and air casting or by vacuum melting and vacuum casting according to recognized melt procedures for cobalt-base alloys, sometimes known as superalloys. Preferably the melt components are used in the form of master alloys to facilitate the melting of the high melting point elements such as wolfram, tantalum, chromium, zirconium, carbon and boron.
In the preferred method of producing the alloy, the original melt formed in the crucible will consist principally of chromium and cobalt. Thereafter, the remainder of the elements required can be introduced into the original melt in any order when the melt temperature is within the range of from about 2,700° F. to about 2,800° F. As an alternate, however, all components of the composition can be introduced into the crucible with the cobalt and chromium. Inasmuch as zirconium and boron are contained in the composition in minimal amounts and certain weight ratios have been indicated desirable, it is preferred that the zirconium, boron, wolfram and tantalum be introduced into the melt immediately prior to pouring in order to prevent either the oxidation of these latter materials or their loss from the crucible. After the addition of these latter materials, the melt is heated to a temperature within the range of from about 2,800° F. to about 3,025° F. to produce a uniform composition at which temperature the melt is poured. The resulting castings can be welded and machined by conventional techniques. Preferably, the cast alloy will be heated at 1,950° F. for three hours and then air cooled prior to further operations.
The following demonstrate the properties of this alloy as compared with that alloy defined in U.S. Pat. No. 3,933,484.
______________________________________ Stress Rupture Tantalum, Life, Hrs. At Creep RateSpecimen Wgt. % 2100° F. & 3000 psi (HR.sup.-1)______________________________________A 1.4 30.0 7.7 × 10.sup.-4B 1.2 31.8 6.0 × 10.sup.-4C 1.0 33.4 1.0 × 10.sup.-3D 0.9 34.7 4.1 × 10.sup.-4______________________________________
These data appear to indicate an improvement in rupture life with decreasing tantalum content. Rather, they indicate that the alloy of the present invention (B, C & D) is as good as the alloy of the prior art (A) since, when experimental error is considered, the above data more correctly are interpreted as indicating that reducing the tantalum content, in actuality, has neither a positive or negative effect on the properties indicated.
The data set forth, above, for the alloy of the prior art represents the use of recycled alloy in use for a period of years. In contrast, the comparative data set out in the 3,933,484 patent were developed using pristine materials. Hence, the data presented here are on a different basis but in no way represent a derogation of the qualities of the alloy as set forth in the patent.
One of the many types of cast articles which can be fabricated employing the alloy of this invention is a spinner. The spinner is fabricated in its entirety of the alloy of this invention.
The spinner is comprised of an upper wall having an opening therein and a lower wall having an opening therein. A continuous peripheral side wall extends between the upper wall and the lower wall to form a substantially circular chamber. The side wall is adapted with apertures which penetrate the side wall and through which molten glass, introduced into the spinner through the opening in the upper wall, is discharged.
As may apply in some spinner types, the opening in the upper wall can be adapted with a flange for connection to means for rotating the spinner. The spinner can also be adapted with an opening in the lower wall for the extension therethrough of fluid introductory means.
It will be evident from the foregoing that various modifications can be made to this invention. Such, however, are considered to be within the scope of this invention.
|
A cobalt-base alloy, particularly suitable for the fabrication of glass spinners and containing up to about 1.2 weight percent tantalum is disclosed.
| 2
|
FIELD OF THE INVENTION
This invention is directed generally to bearing assemblies, and more particularly bushing bearings.
BACKGROUND
Bearing assemblies often include various components including rolling elements that are retained within the assembly to reduce friction and wear between moving parts or surfaces. In some bearing assembly applications, a bushing is used in place of rolling elements to eliminate the necessity for the rolling elements, grease, and retainer. The bushing usually exhibits self-lubricating and shock absorbing properties allowing the bearing to run smoothly and quietly. Often the bushing is made up of a polymer such as Polytetrafluoroethylene (PTFE).
The bushing is often press-fitted inside the bearing assemblies housing, and the bushing is retained by the pressure of the press-fit. In high pressure applications, or in applications where high temperatures are experienced, the bushing will creep during its useful life and the press-fit pressure may be lost. This may result in the bushing rotating within the bearing housing. Other conditions, may also cause the bushing to undesirably rotate within the housing leading to reduced bearing or bushing life.
To prevent any relative movement between the bushing and the housing, some have attempted to use an adhesive to positively lock the bushing within the housing. However, over time and under high temperature, the adhesive has been found to degrade and the bushing may either undesirably come out of the housing, or rotate within the housing. Such methods and results are unacceptable and consequently lead to reduced bearing life and machine downtime.
Another method for retaining the bushing within the housing has been to provide a circumferential groove within the housing and to provide a corresponding bumper on the outer diameter of the bushing. Sometimes this method has been used in connection with an adhesive. In this manner, the polymer bushing is snap fit into the circumferential groove within the housing and retained within the housing. This method may prevent the bushing from moving axially with respect to the housing. However, it does not prevent the bushing from rotating, or spinning within the housing when the adhesive degrades.
Thus, there is a need in the art to provide a bushing that will remain positively retained within the housing.
SUMMARY
The present embodiment is specifically directed to a bushing positioned within a housing that is positively retained to prevent the bushing from moving axially with respect to the housing and that also prevents the bushing from rotating relative to the housing. The present embodiment utilizes a retention pin that positively retains the bushing within the housing.
In an aspect of the present embodiment, a bushing is mechanically locked within a housing to reduce movement of the bushing in axial and circumferential directions relative to the housing. In an exemplary embodiment, a bearing assembly includes at least one retention pin that mechanically locks the bushing within the bearing housing.
In another aspect of the present invention, a locking pin retains an inner ring positioned within an outer ring. The locking pin retains the inner ring from rotating in relation to the outer ring in an axial and circumferential direction. In the exemplary embodiment, the inner ring includes a polymer bushing, and the outer ring includes a housing.
The present embodiments can be utilized in bearings that may be exposed to harsh operating conditions, including subjection to high temperatures and pressure. They provide the ability to retain a bushing within a housing. Consequently, movement of the bushing is reduced in an axial and circumferential direction relative to the housing.
The foregoing and other objects, features and advantages of the bearing or bearing assembly will be apparent from the following more particular description of preferred embodiments as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of an exemplary bushing bearing showing a portion of the retention pin and sleeve;
FIG. 2 is another view of the bushing bearing and retention pin of FIG. 1, without sleeve;
FIG. 3 is a sectional view of the bushing bearing of FIG. 1 that further illustrates the retention pin and retention pin aperture; and
FIG. 4 is a sectional, partial view of the bushing bearing of FIG. 3 further illustrating the retention pin and retention pin aperture.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present embodiment is illustrated in exemplary embodiments that disclose a system and device for reducing movement of a bushing in an axial and circumferential direction. More specifically, the exemplary embodiments have been implemented on a polymer bushing bearing. It should be understood that the present embodiment may be utilized on other bearing types and other bushing materials where a reduced movement of the bushing is desired. Therefore details regarding the bearing are provided as an example, and are not necessary to the invention unless otherwise specified.
FIG. 1 illustrates an exemplary polymer bushing bearing 10 showing a portion of retention pin 14 and sleeve 18 . The sleeve 18 , shown outside of the bearing 10 for purposes of illustration only, is preferably positioned within the bearing 10 along arrows 30 and 32 , such that the sleeve surface 34 is in contact with the polymer bushing 22 . The polymer bushing 22 is positioned and retained within the bearing housing 26 . The polymer bushing 22 is retained within the bearing housing 26 by retention pin 14 . Note that the bearing housing 26 may be configured to accommodate any desired bearing application, and thus the bearing housing 26 should not be limited to the cylindrical configuration such as shown for clarity in FIG. 1 . For example, some bearing housing configurations may be developed for fastening the bearing 10 to another device or object, accepting different types of loads, sealing out contaminants, and so forth.
The sleeve 18 is positioned within the bearing 10 such that the sleeve 18 can rotate in a circumferential direction illustrated by arrows 40 around the central bearing axis 44 . In the exemplary embodiment, the sleeve 18 is a metal alloy, although other materials known in the art may be utilized. A shaft (not shown) may be positioned within and fastened to the sleeve 18 as is known in the art, such as by tightening screws, bolts, clamps, pins, welding, and so on. In an alternate embodiment, the sleeve 18 and shaft are integral to each other to eliminate the need for tightening screws or the other types of fasteners. Note that the sleeve 18 may be configured to accommodate any desired bearing application, and thus the sleeve 18 should not be limited to the cylindrical configuration such as shown for clarity in FIG. 1
In the exemplary embodiment, the bearing housing 26 is a metal alloy, although other materials known in the art may be utilized. The bearing housing 26 can be fastened or mounted to a structure or device (not shown for clarity) such that when the sleeve 18 is rotating, the bearing housing 26 and preferably the bushing 22 is prevented from rotating in the direction of the sleeve 18 . To fasten the bearing housing 26 to a particular structure or device, methods known in the art such as tightening screws, bolts, clamps, pins, welding, and so on for securing the bearing housing 26 to the device may be used. In an alternate embodiment, the bearing housing 26 can rotate rather than sleeve 18 that has been fastened or mounted to a structure or device, depending on the particular bearing application.
Preferably, the retention pin 14 mechanically locks the bushing 22 to the bearing housing 26 . In the exemplary embodiment, the retention pin 14 and the bushing 22 are constructed of Polytetrafluoroethylene (PTFE). According to this embodiment, the retention pin 14 is made from a material similar to the bushing 22 (e.g., PTFE), such that there is little or no additional distresses on the bushing 22 . It should be understood, however, that a stronger retention pin 14 material may be used, for more demanding bearing applications.
FIG. 2 is another view of the bushing bearing 10 and a portion of retention pin 14 of FIG. 1, however the sleeve 18 has been removed in FIG. 2 for purposes of illustration. As described above, the bushing 22 is polymer material such as PTFE, but other materials suitable for these types of bearing applications may be utilized. To retain the bushing 22 within the bearing housing 26 , a retainer pin 14 may be used. Other known mechanisms for fastening or retaining the bushing 22 within the bearing housing 26 such as grooves and adhesive may be used with the retention pin 14 .
FIG. 3 is a sectional view of the bushing bearing 10 of FIG. 1 that further illustrates the retention pin 14 and retention pin aperture 24 . Preferably, the size and configuration of the retainer pin 14 complements the corresponding retention pin aperture 24 . The retainer pin 14 preferably includes a first end 32 and a second end 36 . In the exemplary embodiment, the first end 32 is similar in size and configuration as the second end 36 . Although it should be understood that the first end 32 and the second end 36 can be different in size and configuration, depending on the particular bearing application. Preferably, the retainer pin 14 and the corresponding aperture 24 are made with a degree of precision such that there are low tolerances for a close fit. Adhesives may be utilized to secure the retainer pin 14 in aperture 24 . Moreover, the first end 32 should not project out of the bushing 22 , so that a sleeve (e.g., 18 in FIG. 1) remains in close contact with the bushing 22 and not necessarily the first end 32 of the retention pin 14 .
FIG. 4 is a sectional, partial view of the bushing bearing 10 of FIG. 3 further illustrating the retention pin 14 and retention pin aperture 24 . FIG. 4 illustrates section A—A of FIG. 3 to show the bearing 10 , retention pin 14 , and retention pin aperture 24 from a different viewpoint.
Referring to FIGS. 3 and 4, the retainer pin 14 can prevent the bushing 22 from rotating in either one of the two circumferential directions 40 and in either one of the two the axial directions along central bearing axis (e.g., 44 in FIGS. 1 and 4 ), relative to the bushing 22 . This is especially useful to prevent the bushing 22 from spinning inside of the bearing housing 26 when the sleeve is rotating and the bearing 10 is under high pressure or high temperature conditions. If desired, the retainer pin 14 can be used with other retention methods as are known in the art such as adhesive, grooves, or adhesive and grooves.
According to the exemplary embodiment, the sleeve (e.g., 18 in FIG. 1) is allowed to rotate relative to the bushing 22 in either one of the two circumferential directions. Therefore, the bushing 22 can operate as an anti-friction liner between the sleeve and bearing housing 26 . Preferably, the bushing 22 remains locked in a position relative to the bearing housing 26 to prevent spinning along with the sleeve. To lock the bushing 22 in the axial and circumferential directions, the retention pin 14 is utilized. It is also possible to include more than one retention pin to retain the bushing 22 within the bearing housing 26 , and may be placed anywhere inside of the bushing 22 .
The retention pin 14 is fabricated from a material such as polymer and is sized and configured to the retention pin aperture 24 . The retention pin 14 can be made of other materials such as metals and alloys, depending on the particular application. Stronger materials may be used for more demanding applications. Preferably, the retention pin 14 is made from a material similar to the bushing 22 to reduce any distresses that may arise on the bushing 22 .
According to the exemplary embodiment, the retention pin 14 is preferably inserted into the retention pin aperture 24 after the bushing 22 is positioned within the bearing housing 26 . In this embodiment, the retention pin aperture 24 includes a bushing aperture 62 and a housing aperture 66 . When the bushing 22 is properly positioned within the bearing housing 26 , the bushing aperture 62 and housing aperture 66 preferably align to form the retention pin aperture 24 . A phantom line shows where the bushing aperture 62 and housing aperture 66 align to form the retention pin aperture 24 , and where the bushing 22 and bearing housing 26 meet. The retention pin 14 may be positioned within the retention pin aperture 24 . Moreover, adhesives can be utilized to reduce movement of the retention pin 14 within the retention aperture 24 .
Limits and fits can be used to specify dimensions for the retention pin aperture 24 and retention pin 14 . Two exemplary standards on limits and fits are described by the American National Standards Institute and are given by ANSI B4.1, B4.2, and B4.3. As is known in the art, these standards are divided into classes depending on the desired fit between the aperture and pin. Other methods known in the art can be used to specify dimensions.
In another embodiment, the retention pin 14 can be integral with the bushing 22 . Therefore, upon positioning the bushing 22 within the bearing housing 26 , the retention pin 14 can also be positioned with the retention pin aperture or housing aperture.
In yet another embodiment, the retention pin 14 can be integral with the bearing housing 26 . When the bushing 22 is positioned within the bearing housing 26 , the retention pin 14 can be positioned within the retention pin aperture or bushing aperture.
It should be understood that the processes, methods and systems described herein are not related or limited to any particular type bearing, unless indicated otherwise. Various types of general purpose or specialized bearings may be used in accordance with the teachings described herein.
In view of the wide variety of embodiments to which the principles of the present embodiments can be applied, it should be understood that the illustrated embodiments are exemplary only, and should not be taken as limiting the scope of the present invention. For example, more or fewer elements may be used in the drawings.
The claims should not be read as limited to the described order or elements unless stated to that effect. Therefore, all embodiments that come within the scope and spirit of the following claims and equivalents thereto are claimed as the invention.
|
A bearing directed to a bushing positioned within a housing that is positively retained to prevent the bushing from moving axially with respect to the housing and that also prevents the bushing from rotating relative to the housing. The present embodiment accomplishes these goals by the use of a retention pin that positively retains the bushing within the housing.
| 5
|
BACKGROUND OF THE INVENTION
The present invention relates to laminated resinoid wheels for cutting hard metal materials, a method for continuously producing the resinoid wheels and an apparatus to be used for the method.
Generally, the cutting ability of resinoid wheel varies with the kind of abrasive grains, grain size, kind of binder and porosity. Grinding wheels of various hardnesses have heretofore been produced from a single composition, and a wheel of particular hardness is selected for use in accordance with the material and construction of the articles to be cut. Thus a hard grinding wheel is used for cutting hard metal materials. However, the harder the grinding wheel, the greater will be the cutting resistance encountered, with the result that cutting operation produces a large amount of heat which scorches the cut surface of the material, causing distortion, changes in the hardness of the cut portion and discoloration in the cut surface. Moreover, the irregularities left over along the periphery of cut portion need further finishing procedure. In addition, it is difficult to provide a planar cut surface with a sharp cut edge, whilst the rough abrasive surface is liable to be clogged up to render the wheel no longer operative.
Conventional resinoid wheels have been produced by placing a kneaded resinoid abrasive composition into a die of a given shape, smoothing the surface of the composition with raking means to give a uniform thickness to the mass of the composition, molding the composition at an elevated pressure and baking the molded product. However, this method has the drawback that relatively coarse abrasive grains are caught by the raking means and brought to the surface, rendering the resulting product uneven in grain size distribution. Further according to the conventional method, the raked mass of the starting abrasive composition is pressed on one side for molding. Consequently, the grinding wheel obtained becomes uneven in hardness, inasmuch as the product has high hardness where many coarse abrasive grains are present but low hardness where smaller grains are predominant. When put to use, the grinding wheel wears away more markedly where it contains many fine abrasive grains than where coarse grains predominate, so that an uneven wear takes place. As a result, the grinding wheel not only fails to cut a work straight but is also subjected to an objectionable force and possibly broken in an extreme case. Moreover, if the abrasive composition is not fully raked, the resulting product will have a nonuniform thickness, consequently producing errors when cutting a hard metal material, and a markedly irregular portion of the grinding wheel, if any, will cause an objectionable force to act on and break the grinding wheel during use.
SUMMARY OF THE INVENTION
The present invention has overcome the foregoing problems and provides laminated resinoid wheels, a method for continuously producing the same and an apparatus for practicing the method.
This invention is characterized by a method for producing a laminated resinoid wheel comprising the steps of preparing at least two kinds of abrasive compositions each containing abrasive grains different in size from those of the other composition, placing specified amounts of the abrasive compositions into a die in the form of a desired number of superposed layers respectively, molding the superposed layers into a block, heating the block, rolling the heated block into a sheet, blanking out a circular piece from the sheet and baking the circular piece.
The invention is further characterized by a laminated resinoid wheel produced by the method described above and comprising a core layer made of an abrasive composition containing abrasive grains and at least one pair of layers arranged on the opposite sides of the core layer symmetrically thereof and made of an abrasive composition containing abrasive grains different in size from those of the abrasive composition of the core layer.
The invention is further characterized by an apparatus for automatically feeding a powdery to granular abrasive composition at a constant rate to produce a resinoid wheel according to the method described above, the apparatus comprising an intermittently driven belt conveyor, a slitter having a predetermined width and positioned at an adjustable specified level above the rear end of conveying surface of the belt conveyor, walls provided at the opposite sides of the belt of the belt conveyor and spaced apart in parallel to each other by a distance equal to the width of the slitter to prevent the abrasive composition from dropping, feed means disposed to the rear of the slitter for feeding the abrasive composition onto the belt conveyor, and a downwardly extending feeding tube disposed at the front end of the belt conveyor and pivotally movable in timed relation to the operation of the belt conveyor, the feeding tube opposing a block molding lower die to place the abrasive composition thereinto.
According to the method of this invention, blocks of superposed layers of resinoid abrasive compositions are efficiently rolled into sheets to automatically and inexpensively produce large quantities of various laminated resinoid wheels which are tough, accurate in thickness, free of any distortion and excellent in quality. Since the block of superposed layers of abrasive compositions is passed between multiple opposing pairs of rotating rolls in succession and is thereby rolled into a sheet, the block is subjected to equal pressures on its opposite surfaces. Consequently, the abrasive wheel obtained is uniform in thickness and free of any distortion.
The laminated resinoid wheels obtained by the method of this invention are novel products and comprise laminated layers of abrasive compositions each different in the size of abrasive grains contained therein. A three-layer laminated abrasive wheel, for example, comprises a core layer and layers covering the opposite sides of the core layer and containing abrasive grains smaller than those of the core layer, the core layer thus being harder than the covering layers. Alternatively, the opposite covering layers contain abrasive grains larger than those of the core layer and are therefore harder than the core layer. The abrasive wheel of the former type is capable of cutting large-sized superhard materials such as a large mass of special steel, solid bar measuring 200 to 300 mm in diameter and made of special steel or stainless steel. Since the opposite covering layers are somewhat softer than the core layer in this case, the overall cutting resistance is relatively small and entails reduced heat generation, with the result that a very neat cut surface is obtained without any scorching, distortion and irregularities while the abrasive surface is prevented from clogging. The abrasive wheel of the latter type cuts relatively small hard steel materials within a short time. Although heat will be accumulated in the center portion of the wheel, the soft core layer among the laminated three layers encounters especially small cutting resistance which involves reduced heat generation, so that the overall heat accumulation can be reduced. Accordingly, a very smooth cutting operation can be conducted without irregularities, scorching and distortion in the cut portion, with the abrasive surface rendered free of clogging.
The resinoid wheels of this invention further include a reinforced laminated resinoid wheel which has such construction that a reinforcing sheet material is interposed between the above-mentioned core layer and each of the opposite covering layers as an intermediate layer. The reinforcing sheet material which is glass fiber net, glass cloth or glass mat enables the foregoing three-layer abrasive wheel to exhibit its ability more effectively.
Further included within the scope of this invention are various laminated abrasive wheels having a desired number of abrasive layers. Briefly, the resinoid wheels of this invention comprise a core layer made of an abrasive composition and at least one pair of layers arranged on the opposite sides of the core layer symmetrically thereof and made of an abrasive composition containing abrasive grains which are different in size from those of the core layer.
The apparatus of this invention for feeding the abrasive composition at a constant rate is useful in preparing superposed layers of the abrasive compositions, making it sure to produce the laminated abrasive wheel of this invention continuously in a large quantity.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side elevation showing an embodiment of the overall apparatus for producing a laminated resinoid wheel according to this invention;
FIG. 2 is a schematic plan view showing the same;
FIG. 3 is a side elevation on an enlarged scale showing an apparatus for feeding an abrasive composition to be used in this invention;
FIG. 4 is a view in vertical section of the same;
FIG. 5 is a plan view partly broken away to show a three-layer laminated resinoid wheel of this invention; and
FIG. 6 is a plan view partly broken away to show a five-layer laminated resinoid wheel of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Production of the three-layer laminated resinoid wheel shown in FIG. 5 will first be described.
With reference to FIGS. 1 and 2, abrasive grains of silicon carbide, alumina or siliceous sand, a binder such as phenolic resin, epoxy resin, diallyl phthalate resin or like thermosetting synthetic resin and, when desired, a filler such as creolite, iron disulfide, red iron oxide or clay are fed to two mixers 1 and 1 of the two-stage type (one mixer not shown) in specified amounts respectively to prepare two kinds of abrasive compositions, the abrasive grains in one of the compositions being different in size from those of the other composition. The compositions are supplied to first and second feeders 2 and 2 respectively. The proportions by weight of the ingredients of each composition are 60 to 90 parts of abrasive grains, 10 to 20 parts of binder and 0 to 20 parts of filler. The coarse abrasive grains to be used are 16 to 46 mesh in size, while fine grains are of 60- to 150-mesh size. The abrasive compositions described above contain, for example, 80-mesh abrasive grains and 20-mesh abrasive grains respectively. The compositions may contain different binders and fillers respectively but, in most cases, it is preferable to use the same ingredients for the two compositions.
The abrasive composition containing fine 80-mesh abrasive grains is then fed by the first feeder 2 to the lower die 4 of a block molding machine 3 in the form of a layer having an average thickness of 6 mm. Subsequently, the second abrasive composition containing coarse 20-mesh abrasive grains is fed onto the layer of first abrasive composition in the lower die 4, the second abrasive composition being placed in the form of a layer having an average thickness of 17 mm. Finally, the abrasive composition containing fine abrasive grains is placed over the layer of second abrasive composition in the lower die 4 to an average thickness of 6 mm in the form of layer. Thus a three-layer mass is prepared. The molding machine 3 includes a flat platelike upper die 5 positioned at its center and movable up and down and two boxlike lower dies 4 alternately movable outward from the center and then inward. The upper and lower dies 5 and 4 are heated to a temperature, for example, of 70° to 90°C. The resinoid abrasive masses are subjected by the molding machine 3 to pressure, for example, of 80 to 140 kg/cm 2 for 20 to 60 seconds and is thereby molded in succession into blocks having a size in the range of from 260 × 380 × 25 mm to 400 × 500 × 40 mm. The molded block is then transferred by a chute 6 onto a first conveyor 7, which passes the block through a high frequency heater 8 to heat the block for example at a temperature of 40° to 75°C for 15 to 25 seconds. The block is then sent to a rolling machine P having multiple pairs of rolls. More specifically, a second conveyor 9 continuous with the first conveyor 7 feeds the heated block to first rolls 10. The rolled sheet obtained is then placed onto a first turntable 11, turned 90° and sent by a third conveyor 12 to second rolls 13, whereby the rolled sheet shaped by the first rolls is rolled transversely. The resulting rolled sheet is thereafter carried on a fourth conveyor 14 to third rolls 15 and rolled. The sheet is further transferred onto a second turntable 16, turned 90° and then carried by a fifth conveyor 17 to a fourth unit of four high-precision rolls 18 which are vertically arranged in a row, whereby the abrasive sheet is eventually made into a sheet measuring 400 to 1,200 mm in width and 1 to 15 mm in thickness. The sheet is then fed by a sixth conveyor 19 to a blanking press 20, by which circular pieces are blanked out from the sheet. In the present example, two to four raw circular abrasive pieces are blanked from one sheet. The circular pieces obtained are then placed between polished iron discs and baked in a tunnel type electric furnace or like device at a temperature suitable for the curing of the aforementioned synthetic resin used as the binder. For baking, the circular pieces are heated progressively from room temperature to 180°C over a period of about 1 day. Consequently, a three-layer circular laminated abrasive product is finally obtained which measures 4.5 mm in thickness and 510 mm in diameter and comprises a core layer A containing 20-mesh coarse abrasive grains and opposite outer layers B containing 80-mesh fine abrasive grains as shown in FIG. 5. Preferably, the third, fourth and fifth conveyors 12, 14 and 17 are provided with infrared heaters 22, 23 and 24 for maintaining the uncured abrasive sheet at a predetermined temperature during transport. The second turntable 16 may be turned as when desired to spread the abrasive sheet widthwise for the production of large-sized abrasive wheels. Further as illustrated in FIG. 2, the block molding machine 3 preferably has two lower dies 4 for receiving and compressing the starting compositions alternately so that continuous operation can be carried out very smoothly. Such apparatus is disclosed for example in Japanese Utility Model Application No. 128551/1972 already filed by the present applicant. To assure continuous operation, the blanking press 20 for uncured resinoid abrasive sheet may advantageously be of such construction that circular pieces can be blanked out from the sheet in timed relation to the movement of the sheet. Such apparatus is disclosed for example in Japanese Patent Application No. 111785/1972 already filed by the present applicant.
FIG. 6 shows a five-layer laminated resinoid wheel composed of two kinds of abrasive compositions each containing abrasive grains different in size from those of the other composition and two reinforcing sheets for example of glass fiber net. To produce such resinoid wheel, abrasive grains of different sizes, binder and filler are mixed together by the two mixers 1 and 1. The two kinds of abrasive compositions thus formulated are fed to the lower die 4 of the block molding machine 3 by the two feeders 2 and 2. First, the composition containing fine abrasive grains is placed into the lower die 4 in the form of a 6-mm thick layer. Previously, a glass fiber net having a binder deposited thereon is prepared by immersing the net in a solution of binder and drying. Three or four sheets of the glass fiber net each having a thickness for example of 0.4 to 0.9 mm are placed to a thickness of 0.4 to 4.5 mm over the abrasive composition in the lower die 4. The composition containing coarse abrasive grains is then placed over the glass fiber net, for example, in the form of a 14.5-mm thick layer, over which the same number of sheets of glass fiber net are further placed. Finally the composition containing fine abrasive grains is placed over the glass fiber net in the form of a 6-mm thick layer. The layers in the lower die 4 are then lightly compressed by the upper die 5 to form a block of laminated abrasive composition, which is thereafter treated in the same manner as in the production of the three-layer laminated resinoid wheel already described. Consequently, a circular resinoid wheel is obtained which measures 4.5 mm in thickness and 510 mm in diameter and comprises a core layer A containing 20-mesh coarse abrasive grains, opposite outer layers B containing 80-mesh fine abrasive grains and intermediate layers C of reinforcing sheet as shown in FIG. 6.
If rolls coated with rubber or some other material equivalent thereto such as elastic synthetic resin, copper, lead, soft zinc or like soft metal are employed for the terminal unit of rolls for rolling the block of abrasive composition, the uncured resinoid abrasive piece obtained can be made rough-surfaced on its opposite sides. When baked, the piece will make an improved resinoid wheel.
More specifically, the resinoid bonded grinding wheel thus produced has rough front and rear surfaces with the abrasive grains alone projecting therefrom and therefore exhibits a greatly improved cutting ability. In fact, such grinding wheel is capable of cutting steel pipes and like hard metal materials easily, rapidly and with reduced heat generation to produce a cut surface which is free of burning, distortion and discoloration. The resulting cut-off metal piece is accordingly suitable for the subsequent treatment. In this case the apparatus may advantageously include five pairs of rolling rolls, with the terminal pair of rolls covered with rubber, and an additional high frequency heater disposed immediately before the terminal pair to prevent the rolled sheet from cooling and to render the sheet rough-surfaced on its front and rear sides.
With reference to FIGS. 3 and 4, an embodiment of the feeder 2 for feeding the abrasive composition at a constant rate will now be described.
The abrasive composition prepared by the mixer 1 of the two-stage type is charged into the hopper 30 of the feeder 2. Disposed in the hopper 30 is a blade agitator 31 which is driven by a motor 33 by way of a drive sprocket 32 mounted on the same shaft as the agitator 31 and disposed outside the hopper 30. The abrasive composition is discharged from the bottom outlet of the hopper 30 onto a belt conveyor 36 while being crushed by a two-stage crusher 35 disposed in a compartment 34 positioned under and communicating with the hopper 30. The belt 37 of the belt conveyor 36 is provided at its opposite sides with upstanding walls 38 and 38 which are spaced apart by a given distance in parallel to each other. The conveyor 36 is adapted to be intermittently driven by a motor 39. On the outer side of the front wall of the compartment 34, there is provided a slitter 40 which is positionable at an adjusted level. The upstanding walls 38 and 38 and slitter 40 serve to permit the abrasive composition to be carried on the travelling conveyor 36 uniformly over a definite width, so that a specified amount of the composition can be sent forward by the conveyor being driven for a specified time determined by adjusting an unillustrated timer. At the front end of the belt conveyor 36, there is disposed a feed guide 41 having an opening at its lower end which pivotably carries a feed tube 42. The feed tube 42 is connected by a link 45 to a projection 44 eccentrically mounted on a drive sprocket 43 for the belt conveyor 36. The feed tube 42 is therefore movable back and forth in timed relation to the travel of the belt conveyor 36, whereby the abrasive composition can be placed into the lower die 4 of the block molding machine 3 to a uniform thickness. The lower end of the feed tube 40 is provided with a closure 47 which can be opened and closed by the operation of a cylinder 46. The closure 47 prevents the abrasive composition from dropping from the lower end while the belt conveyor 36 is held out of operation. The upper crusher member 35a of the crusher 35 is driven by a motor 48, whilst the lower crusher member 35b thereof is driven by the motor 33 by way of a sprocket 49 mounted on the same shaft as the drive sprocket 32.
The present invention can be embodied in other different modes without departing from the spirit and basic features of the invention. Thus the embodiments herein disclosed are given for illustrative purposes only and are not limitative in any way. The scope of this invention is defined by the appended claims rather than by the above specifications. All the modifications and alterations within the scope of the claims are to be construed as being covered by the claims.
|
Resinoid wheels are continuously produced by preparing resinoid abrasive compositions each different in the size of abrasive grains contained therein, placing the abrasive compositions into a die in the form of superposed layers, molding the superposed layers into a block, heating the block by a high frequency heater, passing the heated block through multiple pairs of rolls to roll the block into a sheet, blanking out circular pieces from the rolled sheet and baking the circular pieces.
| 1
|
BACKGROUND OF THE INVENTION
The invention relates to improvements in the manufacture of composites of crystalline aluminosilicate zeolite and amorphous alumina-silica in the form of mechanically strong monolithic bodies. The invention relates particularly to an improvement in those processes for producing such composites which involve the in situ synthesis of a zeolite alumino-silicate, such as faujasite, ZSM-5 or mordenite, by reaction of a solution of a base with calcined clay contained in preformed self-supporting monolithic bodies.
Zeolitic molecular sieves are used in a wide variety of catalytic and adsorptive applications. For example, sieves such as faujasites and ZSM-5 are well-known constituents of hydrocarbon conversion catalysts. Other synthetic zeolites such as mordenite are useful as catalysts for the reduction of nitrogen oxides with ammonia. The zeolites are normally synthesized as finely divided high purity crystals. For most purposes the crystals must be bonded with a suitable matrix material such as a silica-alumina gel, clay or mixture thereof, to form particles having good attrition resistance, high heat capacity and thermal conductivity. The choice of a binder for a zeolitic molecular sieve is limited by the fact that the binder must be thermally stable and provide access of gases or liquids to the zeolite crystals in the composite particles.
Zeolitic molecular sieve catalyst or catalyst support particles are supplied in the form of small microspheres, typically particles having an average size of about 60 microns, when they are to be used in fluidized bed processing such as fluidized bed catalytic cracking of gas-oil feedstocks. Generally the particles are in the form of cylinders or spheres that are 1/16 inch or larger when they are to be used in fixed bed processes such as the hydrocracking or hydrotreating of resid hydrocarbons. On the other hand, gas phase reactions carried out at high space velocity and liquid phase reactions of heavy oils are often diffusion limited, i.e., only the outer portion of the catalyst particles is utilized. Catalysts for such reactions are desirable in the form of thin-walled honeycombs. Irrespective of the specific form or shape of the catalyst or absorbent bodies, it is generally desirable to provide the structures in the form of rigid, attrition-resistant bodies in which zeolite crystals are uniformly disseminated in a porous heat-stable matrix.
The synthesis of zeolites from calcined clays, especially kaolin clay, is known. For example, it is well known that metakaolin (kaolin clay calcined at a temperature of about 1200° to 1500° F.) will react with sodium hydroxide solution to produce sodium zeolite A. It is also known that when kaolin is calcined under more severe conditions, sufficient to undergo the characteristic exothermic reaction, for example 1700° to 2000° F., the calcined clay will react with sodium hydroxide solution, small amounts of metakaolin preferably being present, to synthesize faujasite-type zeolites. Reference is made to the following commonly assigned patents of Haden et al: U.S. Pat. Nos. 3,335,098 and 3,338,672. As an offshoot of these discoveries processes were invented that resulted in shaped bodies that were composites of a mixture of crystals of faujasite-type zeolites and porous silica-alumina matrix. The composites were synthesized directly in the form of shaped particles, in particular fluidizable microspheres, from preforms composed of kaolin clay calcined to undergo the exotherm. This was accomplished by immersing the preforms (microspheres of kaolin clay calcined at high temperature) in a solution of sodium hydroxide to form a slurry, aging the slurry, typically for 4-8 hours at 100° F. and then heating to crystallize the zeolite within the preforms. Silica originally in the microspheres was leached or extracted during the reaction, producing a sodium silicate mother liquor and leaving a porous matrix in the zeolitized microspheres. Because the composite bodies were zeolitized directly without a separate binding step to composite zeolite and binder, the processing has become known as the "in situ" process. Reference is made to the following commonly assigned patents of Haden et al: U.S. Pat. Nos. 3,391,994, 3,433,587, 3,503,900 3,506,594, 3,647,718 and 3,663,165 and 3,932,268.
It is now known that the in situ technology can be utilized to convert bodies of kaolin clay calcined to undergo the exotherm into composite bodies in which the zeolitic component is other than a member of the faujasite family. For example, the crystalline aluminosilicate component can be synthetic crystalline mordenite or ZSM-5 type zeolites. Reference is made to U.S. Pat. No. 4,091,007 to Dwyer et al and to our copending U.S. application Ser. No. 864,731 dated Dec. 27, 1977 and now abandoned, the entire disclosures of which are incorporated herein by cross-reference. Further, it has also been discovered that calcined clay-containing precursor bodies and ultimate zeolitized products can take forms other than fluidizable microspheres. For example, the bodies may be cylindrical pellets, berl saddles or they may even have complex intricate shapes such as multi-channeled structures or honeycombs. Reference is made to our copending application Ser. No. 856,658 filed Dec. 2, 1977 and now abandoned, the entire disclosure of which is also incorporated herein by cross-reference and to U.S. Pat. No. 4,091,007 (supra).
Irrespective of the zeolite to be synthesized by in situ reaction between preformed bodies composed of kaolin clay calcined to undergo the exotherm and basic solutions, the source of clay and the calcining conditions have a significant effect on the process. Calcination of hydrated kaolin clay results in dramatic changes in the reactivity of the clay towards both bases and acids. Especially when the clay is calcined at temperature sufficiently high to undergo the exotherm, the reactivity of the calcined clay is remarkably sensitive to the source of the hydrated clay employed as a starting material and reactivity is also highly sensitive to calcination conditions. For reasons not presently understood even high purity kaolin clays from different sources frequently react differently towards acids and bases when calcined under essentially the same conditions and in the same equipment. The difference in reactivity towards basic solutions is reflected in rate of reaction and/or by the composition and quantity of the crystalline zeolitic aluminosilicate present in the zeolitized bodies. This can present quality control problems of considerable magnitude. For example, in the manufacture of a faujasite cracking catalyst it is generally desirable to synthesize a faujasite component having a consistently high SiO 2 /Al 2 O 3 and in a consistent quantity. In practice this means that when the manufacturer of a cracking catalyst utilizing the in situ approach employs a new source of clay, an undesirably low zeolite content may be found in the zeolitized bodies or the SiO 2 Al 2 O 3 of the zeolite component may be less than desired. This may also occur when there are fluctuations in the operation of the calciner.
Sensitivity of the in situ processing to variations in clay and calcination conditions is minimized to a certain extent by including a small amount of the form of calcined clay generally referred to as "metakaolin" in the reaction mixture. As noted in several of the patents cited above, metakaolin is prepared under conditions that are relatively mild compared to those employed when the clay undergoes the exotherm. While the addition of metakaolin has the effect of "smoothing out" the process, it does not assure that the desired zeolite content and zeolite composition will be achieved under any conditions, much less at an acceptable production rate, irrespective of the clay source and the conditions employed when the green clay bodies are calcined to undergo the exotherm.
Practice of present invention incorporates the feature of carrying out the reaction between the shaped precursor bodies of calcined clay and aqueous reaction liquid in the presence of added nucleation centers, i.e., a dilute aluminosilicate solution, generally of a colloidal nature, and chemically akin to the crystalline zeolite that is to be synthesized. Such nucleation centers, frequently referred to as "seeds" or crystallization "directors", have been used in a wide variety of crystallization operations. These have included processes for preparing zeolitic aluminosilicates of the synthetic faujasite type. In accordance with the teachings of U.S. Pat. No. 3,808,326 nucleation centers are used in the synthesis of so-called zeolite Y (U.S. Pat. No. 3,130,007) from active SiO 2 /Al 2 O 3 gels. As a result, inception time and reaction rate are reduced. Solutions of nucleation centers are also used in the process of U.S. Pat. No. 3,671,191 but they are employed with a mineral acid to prevent silica solubilization by excess caustic, the acid thus allowing growth of higher SiO 2 /Al 2 O 3 faujasite. Without the nucleation centers, too long a reaction time would result. Crystalline nucleation centers are utilized in practice of the invention of U.S. Pat. No. 3,574,538. This is in contrast to the amorphous nucleation centers employed in the processes of the above patents. U.S. Pat. No. 3,547,538 teaches that heat accelerates maturation of nucleation centers. Again, the nucleation centers are employed simply to increase reaction rate of faujasite-type zeolites. U.S. Pat. No. 3,492,090 also concerns a seeded reaction for production of synthetic crystalline zeolites of the faujasite type. The feature of this patent is that after addition of nucleation centers and silica-alumina gel the mixture is deliquored and the solid cake is reacted at 200° F. Reduction in material handling is cited as the advantage. In U.S. Pat. No. 3,777,006 metakaolin is mixed with sodium silicate to correct for differences in SiO 2 /Al 2 O 3 between the clay and the desired crystalline zeolite Y reaction product. The mixture is formed into particles, dried for 16-24 hours to impart hardness, and then reacted with caustic and a solution of nucleation centers to produce particles composed essentially or substantially so, of zeolite Y. British Pat. Nos. 1,271,450 and 1,342,977 deal with processes generally similar to the one described in U.S. Pat. No. 3,777,006. In the processes of the British patents, the metakaolin and sodium silicate (or silica-alumina gel) are formed into small fluidizable spheres by spray drying slurries of the mixtures. In the former patent (U.S. Pat. No. 1,271,450), the zeolitic nucleation centers are included in the slurry feed to the spray drier and the spray dried product is reacted with caustic to form zeolite. In the latter patent (U.S. Pat. No. 1,342,977), the seeds are added after spray drying to the caustic reaction slurry. The method allegedly allows formation of harder particles, since the particles can be calcined after spray drying without fear of affecting seed integrity.
THE INVENTION
The present invention comprises the in situ synthesis of a zeolitic aluminosilicate molecular sieve within a preformed calcined kaolin clay shaped body or bodies by reacting the preformed body or bodies with an aqueous solution of a base to effect the synthesis, the reaction being carried out in the presence of a solution of zeolitic nucleation centers of colloidal dimension. During the synthesis, substantial silica and/or alumina is leached from the preformed body or bodies by the basic solution. This results in adequate diffusion during synthesis and then imparts desirable porosity in the amorphous alumina-silica component of the finished molecular sieve crystal containing body. Leaching of silica and/or alumina provides diffusion paths in the bodies to and from the zeolitic molecular sieve crystals disseminated therein.
In a presently preferred embodiment the invention comprises a process in which nucleation centers are added to a mixture of microspheres of kaolin clay that have been calcined at elevated temperature to undergo the characteristic exotherm and caustic solution. The seeds increase growth rate, desensitize the growth rate dependence on microsphere quality and provide a simple means to consistently produce fluid cracking catalyst particles having a desired high SiO 2 /Al 2 O 3 ratio zeolite. In fact, practice of an especially preferred embodiment results in novel composite cracking catalysts having SiO 2 /Al 2 O 3 considerably higher than those obtained by prior art in situ processing.
Practice of the present invention represents a significant departure from the practice of prior art crystallization processes using seeds. Processing problems unique to the production of composite zeolitic bodies from precursor bodies composed of high temperature calcined clay were not faced by prior art workers who did not use such form of clay and were not concerned with sensitivity of zeolite crystallization to source of clay and calcination history. By practice of the invention these unique problems are overcome or at least minimized. Furthermore, the invention provides means for the manufacture of a variety of composite synthetic crystalline zeolitic bodies not capable of being produced on a consistent production scale basis by prior art "in situ" zeolite composite synthesis, as described above.
In general, the difference between prior art and the present invention lies in the fact that the use of seeds and subsequent reaction chemistry are tailored to the unique characteristics of in situ processing of bodies composed of clay calcined to undergo the exotherm. Use of seeds in accordance with this invention provides ease of processing, higher SiO 2 /Al 2 O 3 ratios than often result when seeds are not used, and, remarkably, desensitization to microsphere calcination and clay source. Use of seeds in the prior literature was to accelerate formation of zeolite and not to provide ability to use reagents of varying quality or to improve product quality. Therefore the advantages found with the use of seeds in in situ processes were not expected or predictable based on prior art. In fact, those knowledgeable in theoretical concepts relative to the mechanisms by which seeds accelerate crystallization will find it unexpected that seeds have any effect much less a significant effect, on crystals forming within rigid coherent bodies that have a substantial mass compared to that of individual crystals that are eventually generated with such bodies.
In contrast with the process of the invention, the sole advantage of using seeds in carrying out the technology described in U.S. Pat. No. 3,808,326 (supra) is to reduce crystallization time. Similarly, the instant invention is basically different from practices described in U.S. Pat. Nos. 3,671,191 and 3,574,538. These patents also deal with seeded reactions involving silica alumina gels and not preformed calcined kaolin bodies such as microspheres. As for U.S. Pat. No. 3,574,538, seeds are used to increase reaction rate and bodies of kaolin calcined at high temperature (e.g. 1800° F.) are not employed. Microcrystals, as required in practice of the invention of U.S. Pat. No. 3,574,538, would be unsuitable in the process of the present invention because of the size of the precursor reaction bodies and the chemistry involved. The principles of U.S. Pat. No. 3,492,090, would obviously be inapplicable to the present invention. In contrast to the teachings of U.S. Pat. No. 3,777,006 in which metakaolin and sodium silicate are reacted in a seeded environment to produce pure zeolite Y, our process uses high temperature calcined microspheres which furnish the silica and alumina reactants and which are converted only partially (e.g., 10 to 30%) to faujasite. Referring now to British Pat. Nos. 1,271,450 and 1,342,977 in which metakaolin and seeds are used in a process including a spray drying step, it is apparent that even when carrying out that presently preferred embodiment of the present invention in which a faujasite catalyst is prepared by spray drying clay, calcining the resulting spray dried microspheres and reacting the calcined clay in microsphere form with sodium hydroxide in a seeded environment, results and benefits not possible by the teachings of the British patents are achieved.
DESCRIPTION OF PREFERRED EMBODIMENT
The principles of this invention and practice thereof are applicable in general to any process for converting a preformed body or bodies composed of high temperature calcined kaolin into a body or bodies composed of a mixture of crystals of at least one crystalline zeolitic aluminosilicate uniformly disseminated throughout one or more porous non-zeolitic silica/alumina phases, which process involves immersing the preformed body or bodies in a solution of one or more bases, optionally aging, and heating the mixture until zeolite crystals are formed in the bodies. By way of example, the base may be sodium hydroxide solution or mixed sodium hydroxide--quarternary ammonium bases, depending on the crystalline zeolite that is desired. Concentration of the base and proportion of basic oxide, e.g., Na 2 O, in the solution relative to SiO 2 and Al 2 O 3 in the calcined bodies, also influences the composition and quantity of zeolitic aluminosilicate. Such processes are described in the Haden et al patents and the Dwyer et al patent cited above, and in the pending applications, the teachings of which have been incorporated herein by cross-reference.
The zeolitic nucleation centers used in carrying out our invention are colloidal zeolitic precursors grown from mixed sodium aluminate-sodium silicate solutions. Suitable solutions of nucleation centers are described in U.S. Pat. Nos. 3,803,326, 3,777,006, 3,574,538, 3,886,094 and 3,671,191. Generally the solutions useful when the preforms are zeolitized to contain a molecular sieve of the faujasite family will contain 90-92 mole % water and are tightly bunched at the center of the high SiO 2 /Al 2 O 3 faujasite phase field for zeolite growth from gels. When mordenite is desired the composition will be appropriately enriched in silica to correspond to the composition of synthetic mordenite. In most cases, solutions of zeolitic nucleation centers are grown (aged) at or below room temperature and are maintained at a temperature below about 100° F., preferably below about 90° F., and most preferably at about 60° F. to 75° F. to avoid gelation before being added to the mixture of preformed bodies and solution of base. Presently preferred are solutions of nucleation centers in which the sub-micron size particles of sodium aluminosilicates are amorphous (to X-ray). Satisfactory solutions have been prepared by the following methods:
(1) Twenty-six (26) g. of Al 2 O 3 .3H 2 O were dissolved at 180° F. in a solution of 158 g. of NaOH in 558 ml. of water. The solution was cooled to 60° F. and 555 g. of N®-brand sodium silicate (8.9% Na 2 O, 28.8% SiO 2 , 62.3% H 2 O) was slowly added. Reaction temperature did not exceed 70° F. The mixture was aged in a sealed container overnight at ambient temperatures of about 70°-75° F. before being used as nucleation centers.
(2) Twenty-six (26) g. of Al 2 O 3 .3H 2 O was dissolved in a solution of 100 g. of NaOH in 455 ml. of water. This solution was cooled to 60° F. and 400 g. of a sodium disilicate solution (28.8% SiO 2 , 8.9% Na 2 O and balance H 2 O) was slowly added. The system was then allowed to sit 3-4 hours before use.
(3) Ten and eight-tenths (10.8) g. of Al 2 O 3 .3H 2 O was dissolved in a solution of 32 g. of NaOH in 200 ml. of water. This solution was cooled to 100° F. and added to a resin flask containing 167 g. of a sodium disilicate solution (28.8% SiO 2 , 15% Na 2 O, and balance H 2 O). The system was stirred 10 minutes and the mixture was then allowed to sit 3-4 hours at ambient temperatures before use.
A difference between typical prior art seeded zeolite synthesis from gels and use of nucleation centers in the present invention is that the in situ processes to which the invention is applicable usually require from 10-100% more nucleation centers for them to be effective than when nucleation centers are used in conventional manner to accelerate formation of discrete zeolitic crystals from gels. The reason is not known.
Irrespective of the specific size and shape of the zeolitized bodies or technique that is employed to place hydrated kaolin feed into the form of self-supporting green shaped bodies consisting of hydrated kaolin clay, the green bodies are calcined, preferably at 1700° to 2000° F., for a time sufficient to dehydrate the clay. During heat treatment the hydrated kaolin clay undergoes the characteristic kaolin endotherm associated with dehydration when it is heated to a temperature of about 1350° F. Subsequently the resulting metakaolin undergoes the characteristic exothermic reaction when it is heated to a temperature of about 1800° F. It is essential to calcine the preformed bodies at a temperature of 1700° F. or above in order to convert them to a state or condition such that they are useful in the synthesis of a catalytically suitable zeolite such as faujasite, mordenite or ZSM-5. Lower temperatures such as 1350° F. will generally limit zeolite synthesis to the formation of zeolites such as type A (U.S. Pat. No. 3,883,243) unless an additional source of silica, for example sodium silicate, is employed as a reactant. Furthermore, temperatures of 1700° F. or above lead to the formation of zeolitized bodies that will be considerably stronger than those obtainable at lower temperatures, e.g., 1350° F. On the other hand, temperatures appreciably above 2000° F. result in recrystallization of silica and/or alumina phases which generally are deleterious to the reactivity of the components in the precursor bodies with basic solutions. Thus the calcined preforms are preferably amorphous or essentially so when tested by a conventional X-ray diffraction technique (see the Haden et al patents supra).
Bases known to be useful in zeolite synthesis, including alkali metal hydroxides, ammonium bases, as well as mixtures thereof, may be employed in practice of the invention. The base or mixture of bases are dissolved in water and the solution added in amount at least sufficient to cover the preformed bodies to be zeolitized. Depending on the zeolite to be synthesized, soluble sources of silica and/or alumina may be added to the aqueous reaction medium. Generally aqueous solutions of 2 to 30% weight concentration are used. The amount of solution, controlled to provide the desired ratios of alkali (and/or ammonium oxide) to Al 2 O 3 .2SiO 2 in the calcined preformed bodies, will obviously vary with the zeolite that is to be synthesized within the bodies and with the concentration of the solution of the base.
Generally the reactions are carried out at atmospheric or elevated pressure at elevated temperature for a time sufficient to achieve crystal formation within the preformed bodies. In the case of faujasite synthesis, a lower temperature (aging step) may precede the high temperature crystallization. The zeolite is crystallized in hydrated form.
The desired quantity of the zeolite component in the crystallized bodies will vary with intended end use. When used as cracking catalysts the zeolitized bodies will contain about 2 to 75%, most preferably 10-50%, crystalline zeolite as determined by X-ray diffraction. It should be noted that complete conversion of the bodies to zeolite is avoided since the structures may lack mechanical strength and diffusivity imparted by the porous nonzeolitic alumina-silica matrix constituent.
After synthesis the bodies may be subjected to ion exchange treatment in known manner to replace cations present as a result of synthesis with more desirable cations. For example, exchangeable sodium may be reduced to 1% or below by ion exchange with ammonium salts, ammonium and rare earth salts or alkaline earth metal salts.
In some cases, the crystallized bodies, which may have undergone ion exchange, are used as a support for a catalytically active metal or metal compound, for example platinum, which may be incorporated by ion exchange, impregnation or a combination thereof.
The presently preferred embodiment of the invention is directed to improving the manufacture of cracking catalyst particles in the form of fluidizable small (microspheres) from precursor bodies prepared by spray drying an aqueous slurry of hydrated kaolin clay to form microspheres, and calcining the microspheres at temperature and for a time sufficient for the hydrated kaolin to dehydroxylate and then undergo at least partially the characteristic exotherm. The microspheres are formed into a slurry by mixing them with sodium hydroxide solution generally of 15% to 20% weight concentration, the solution containing from about 0.45 to 0.75 moles Na 2 O per mole Al 2 O 3 in the microspheres. The SiO 2 /Al 2 O 3 molar ratio of the microspheres will depend on the source of clay and is generally about 2/1, corresponding to the theoretical SiO 2 /Al 2 O 3 of minerals of the kaolin clay family (kaolinite, halloysite, dickite, etc.). Optionally metakaolin is present in the slurry.
It is preferable to add seed solution, described below, to a performed slurry containing components required for zeolite crystallization in the microspheres although the seed solution may be added before this is done. The components of the slurry including the seeds may be aged, for example held at about 100° F. for 4 to 12 hours, but this is optional when practicing the invention. Whether or not an aging step is included in the process, the seeded slurry is heated until a desired amount, usually at least 5%, preferably at least 15%, and most preferably at least 20% zeolite of the faujasite family is crystallized. Generally the reactants are selected to synthesize a faujasite having a SiO 2 /Al 2 O 3 of at least 4.0, preferably at least 4.5 and most preferably 5 or above. (Zeolite content is estimated in conventional manner from X-ray patterns and SiO 2 /Al 2 O 3 is determined from the patterns using the known Freeman et al curve). Suitable temperatures for the heat treatment are described in the Haden et al patent. Mother liquor (sodium silicate solution) is removed at least partially from the microspheres, which are then ion-exchanged to reduce Na 2 O to about 1% or below, preferably below. Ammonium ions, mixed rare earth-ammonium ions, or rare earth ions are recommended for the ion-exchange(s).
Since the zeolitized bodies prepared by the in situ method are remarkably attrition-resistant, as emphasized above, the zeolite and nonzeolitic component(s) of such bodies cannot be separated from each other by known techniques. Therefore the precise chemical composition of the crystalline zeolitic component cannot be determined by conventional analytical techniques. However, the general structure of the crystalline component may be determined from X-ray patterns. By correlating information obtained from the pattern with published values obtained for X-ray patterns of pure zeolitic aluminosilicates with chemical composition of the corresponding pure zeolites, chemical analysis of the zeolite, e.g., SiO 2 /Al 2 O 3 may be estimated. Therefore, it will be understood that all values of SiO 2 /Al 2 O 3 and percent zeolite referred to herein are values obtained by interpretation of X-ray diffraction patterns as described in the Haden et al patents (supra).
The following examples are given to illustrate various forms of the presently preferred embodiment of our invention and to show certain advantages. The examples, all dealing with conversion of calcined kaolin clay microspheres to produce composite faujasite-containing fluid cracking catalyst particles, are not to be construed as limiting the invention to the specific reactants and reaction conditions since our invention has broader utility, as indicated above. For example, seeds may be used to grow mordenite or ZMS-5 type zeolites from preforms of high temperature calcined clay, the preforms being in the form of microspheres, cylindrical pellets or even honeycombs.
In the examples, the term "MK" refers to microspheres obtained by spray drying hydrated kaolin clay of high purity and calcining the resulting microspheres in air under conditions of time and temperature to convert the clay into metakaolin. The term "HTM" refers to microspheres calcined in air for a time and temperature to cause the kaolin to undergo the exotherm without mullite formation. Reference is made to the Haden et al patents (supra).
EXAMPLE I
This example shows the effects of variations of clay source and calcination conditions on crystallization of zeolite in preformed microspheres of calcined clay. The following example (Example II) demonstrates how seeds compensate for such variations.
Microspheres for the crystallization reaction were prepared by calcining portions of a sample of "MK" microsphere at 1800° F. in air for 21/2 hours to convert them to "HTM." The "MK" microspheres were obtained from a low iron Georgia kaolin clay of the type known to produce high quality faujasite-containing cracking catalysts by the in situ method and normally used to prepare such catalysts. It is known that calcination of "MK" at 1800° F. will result in a different amount of zeolite and a zeolite of different apparent SiO 2 /Al 2 O 3 (X-ray analysis) than will be realized if calcination is at 1875° F. and all reaction conditions are otherwise maintained constant. However, fluctuations during calcination in a commercial plant can result in local overheating of part of the clay charge or even overheating of the entire charge and thus result in undesired overcalcination.
The procedure was repeated with calcined microspheres made from Georgia gray clay (an ultrafine particle size high iron content kaolin). Experience has shown that this particular clay is not a suitable source of clay for the in situ process. The microspheres of gray clay were calcined at 1800° F. for 21/2 hours under conditions identical to those utilized in the calcination of the other microspheres.
Four hundred and seventy five of each of the above microspheres and 25 g. of "MK" were charged to three 500 ml. resin flasks along with 600 ml. of deionized water and 122.5 g. of caustic (17% NaOH solution). The slurries were aged for 6 hours at 100° F., and crystallized at 180° F. After crystallization the sodium silicate mother liquor was drained from the crystallized microspheres and the microspheres were washed and dried. The objective was to convert the microspheres to a product containing 25% zeolite having a SiO 2 /Al 2 O 3 of at least 4.5, as determined by X-ray analysis using the Freeman et al curve. Results are given in Table I.
TABLE I______________________________________EFFECT OF CLAY SOURCE & CALCINATIONCONDITIONS ON ZEOLITE FORMATION -UNSEEDED REACTIONS Micro- sphere Crystal- Calci- Aging lization Relative Zeolite nation Time Time, % SiO.sub.2 / Temper- Hrs at Hrs at Zeolite Al.sub.2 O.sub.3Clay ature 100° F. 180° F. (X-ray) (X-ray)*______________________________________(A) Normal 1800° F. 6 17 21 4.3 Kaolin(B) Normal 1875° F. 6 40 5 -- Kaolin(C) Gray 1800° F. 6 40 8 -- Clay______________________________________ *Freeman et al curve.
Data in Table I shows that only when the normal source of clay was used and calcination was at 1800° F. (A) did the desired quantity of zeolite form with less than 25 hours aging and crystallization time. When the normal source of clay was used but the microspheres were overcalcined (B) and when (C) was employed and the microspheres were calcined at 1800° F. reaction rates were poor and the quantity of zeolite formed was unacceptable.
EXAMPLE II
Microspheres prepared as above were then reacted using seeds. This was accomplished by adding 380 g. of the calcined (A, B or C) microspheres and 20 g. "MK" microspheres to a solution consisting of 300 ml. of deionized water, 64 g. of NaOH, and 400 gm. of a seed solution prepared according to recipe 2. The slurry was crystallized at 180° F. without being aged. Results are given in Table II.
TABLE II______________________________________EFFECT OF CLAY SOURCE & CALCINATIONCONDITIONS ON ZEOLITE FORMATION-UNSEEDED REACTIONS Micro- sphere Crystal- Calci- Aging lization Relative Zeolite nation Time Time, % SiO.sub.2 / Temper- Hrs at Hrs at Zeolite Al.sub.2 O.sub.3Clay ature 100° F. 180° F. (X-ray) (X-ray)*______________________________________Normal 1800° F. 0 9 25 4.70KaolinNormal 1875° F. 0 10 25 4.71KaolinGray 1800° F. 0 10 23 4.69Clay______________________________________ *Freeman et al curve.
A comparison of data in Tables I and II clearly show that use of seed solution greatly improved reaction consistency and product quality despite variations in microsphere clay and calcination temperature. Since the reasons certain clays tend to be less reactive and kaolin must be calcined within a certain temperature range in order to crystallize at least 20% faujasite-zeolite are not known, the positive effect of seeds in overcoming this limitation cannot be explained. While initiation of zeolite formation was facilitated by seeds, the reactants required for the formation of the zeolite came from the calcined clay microspheres as well as the seed slurry.
EXAMPLE III
This example illustrates the preparation of a sodium-form intermediate of a cracking catalyst with a high content of a faujasite type zeolite having a high SiO 2 /Al 2 O 3 .
To a resin flask containing seed solution prepared according to seed recipe 3, was added 380 g. "HTM," 20 g. "MK," 300 ml. of water, and 60 g. of NaOH. The mixture was stirred and heated at 180° F. for sixteen hours. The microspheres were collected by suction filtration, washed and analyzed. X-ray analysis showed the product to contain 30% faujasite zeolite with a SiO 2 /Al 2 O 3 ratio of 5.02 (Freeman et al curve).
EXAMPLE IV
This example illustrates an especially preferred manner of practicing the invention in which a sodium-form intermediate of a fluid cracking catalyst containing about 20% faujasite-type zeolite having an exceptionally high SiO 2 /Al 2 O 3 was prepared.
A solution of nucleation centers was prepared by mixing 135.3 g. sodium aluminate solution (13.74% Na 2 O, 3.88 Al 2 O 3 , 0.2% SiO 2 , balance water) with 47.0 g. of sodium hydroxide solution (24.1% NaOH) and 54.0 g. deionized water. This solution was mixed with 175.6 g. of a sodium dissilicate solution analyzing 15.1% Na 2 O, 0.17% Al 2 O 3 , 29.1% SiO 2 , balance water. Prior to mixing the solutions were cooled to 59° F.±1° F. The solutions were mixed slowly, whereby the maximum temperature was about 62° F. The resulting solution was aged for 16 hours at room temperature (72°-76° F.) before being used to provide nucleation centers for synthesizing high SiO 2 /Al 2 O 3 in microspheres of calcined clay.
The calcined clay microspheres were prepared by spray drying a slip of high purity Georgia kaolin clay, substantially as described in the Haden et al patents, and calcining the microspheres at about 1800° F. to undergo the kaolin exotherm.
Synthesis of zeolite in the microspheres consisting of calcined clay was as follows: Four-hundred (400) g. of the solution of nucleation centers was placed in a one liter Pyrex resin kettle. The following were added in the order listed, with rapid stirring: 186.2 g. of 24.1% solution of sodium hydroxide, 72.5 g. deionized water and 400 g. calcined microspheres. The slurry was heated to 180° F. for 28 hours while it was stirred at a moderate rate, sufficient to keep the microspheres in suspension. The slurry was filtered under vacuum to remove mother liquor and the filter cake was washed with 2400 ml. deionized water and dried overnight at 110°±5° C. Three batches of crystallized microspheres were obtained by this procedure.
An X-ray diffraction scan of a composite of the batches was obtained over the range 30°-33° 2θ using technique described in the Haden et al patent. The unit cell size of the crystalline component was calculated from measurement of peaks on the X-ray pattern and SiO 2 /Al 2 O 3 was calculated using the formula given by Freeman et al. Zeolite content was estimated from heights of X-ray diffraction peaks. Zeolite content was about 20% and SiO 2 /Al 2 O 3 was 5.36.
|
An improved process for the production of mechanically strong shaped crystalline zeolitic aluminosilicate bodies from precursor bodies composed of kaolin clay calcined at elevated temperature, the crystallized bodies having essentially the same size and shape as the precursor bodies. Conversion of the calcined clay contained in the precursor bodies to a mixture of crystalline zeolitic alluminosilicate component and a porous amorphous silica-alumina component takes place as a result of reaction between the calcined clay and an aqueous alkaline liquid in which the bodies are immersed. The improved process features the presence of a solution of aluminosilicate nucleation centers during such reaction.
| 8
|
BACKGROUND OF THE INVENTION
Electrophoresis is a process in which macromolecules are separated on the basis of their charge-to-mass ratios by forcing them to move through a gel by means of a voltage gradient applied across the gel. Those species having uniform charge-to-mass ratios, such as DNA and RNA, are sorted according to their sizes, since the smaller molecules are able to move through the gel matrix more rapidly.
There are two basic formats used routinely in apparatus for electrophoresis of DNA: vertical and horizontal units. The vertical units, in which the gels are cast between two vertical non-conductive plates, offer greater reproducibility because of the uniform gel configurations created by the plates. They also allow for the application of larger sample volumes due to the fact that the sample wells are cast in the same plane as the gels, while the wells in horizontal units are cast into the thickness of the gels. The horizontal units offer greater ease in casting the gels, and do not require the troublesome precautions against leaking associated with the vertical units.
The present device incorporates the advantages of the vertical unit with the ease of operation of the horizontal unit by the addition of a novel plate which forms an upper boundary on the surface of the gel slab. Other such top plates have been described for horizontal electrophoresis units (see, e.g., Elson, D., and Avital, S., U.S. Pat. No. 3,888,759), but they do not address the problems of restricted sample volumes. Their apparatus also requires a larger number of elements, making it relatively complicated to set up. In the present invention, the top plate serves not only to provide a smooth, uniform gel, it also provides a vertically oriented application well that allows for the same sample volumes normally associated with vertical apparatus. In addition, it is notably simpler in operation than that described by Elson and Avital.
There are several other advantages to the use of such a top plate, both in general and in respect to the use of the resultant gels in the subsequent blotting procedures. First, the uniform cross-section of the gel provides a more reproducible electrophoretic pattern. Second, the top plate serves as a thermal insulator so that when the agarose gels are cast, the rate of cooling is reduced, thus reducing convection as the gel sets. This also provides a more uniform gel. Third, gels only 0.15-0.3 mm thick can be cast reproducibly, and this allows for more rapid separation of DNA fragments and also more rapid transfer of these fragments during the subsequent blotting procedure. Fourth, the flat upper surface is desirable for the subsequent blotting procedure, in which a thin membrane is placed in contact with the gel surface.
The present invention also embodies a feature found previously only in vertical gel units: the ability to cast two-gel systems. These two-gel systems are used routinely in high-resolution procedures such as the well-known Laemmli technique (Laemmli, U. K., Nature, 1970). Such procedures offer the advantage of tighter, more concentrated bands in the electrophoresis gel, and hence a more rapid, higher resolution blot. The present invention uses a space-filling element or a blank in place of one portion of the top plate, causing the gel material to be excluded from a portion of the gel tray. After the gel has set, the space-filling element may be removed and another suitable gel material cast contiguously in the space so provided.
In the present device the tray in which the gels are cast performs an additional function. It is used to carry the gel from the electrophoresis unit to the blotting unit and the gel may be left on the tray throughout the blotting procedure. This greatly increases the ease with which the operator can handle the gels. It also allows for the use of much thinner gels, with the benefits common to such gels. In fact, this makes it possible to use thinner gels, and at lower gel concentrations, than is currently possible with either vertical or horizontal systems.
It is, therefore, an object of the current invention to provide a method and an apparatus for casting thin horizontal electrophoresis gels that shall have increased sample capacity.
It is another object of the present invention to provide a means of casting two-gel systems in a horizontal unit.
It is another object of the current invention to provide horizontal gels of uniform, well-defined cross sections and smooth, flat surfaces.
It is a further object of the present invention to provide a means by which gels of lower concentration and having thinner cross sections than is possible with present techniques may be cast, electrophoresed, and blotted conveniently.
A further object of the present invention is the provision of a novel method and apparatus for molding a thin gel slab and a contiguous high volume sample well simultaneously.
Other features and advantages of the present invention will become more apparent from an examination of the following specification when read in conjunction with the appended drawings, in which;
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the assembled gel mold with the well template shown in the molding position in solid lines and poised for insertion in dashed lines;
FIG. 2 is a perspective view of the bottom mold tray;
FIG. 3 is a perspective view of inside of the top mold tray;
FIG. 4 is a vertical section through the assembled mold of FIG. 1 as observed in the direction of the arrows 4--4, showing a molded gel slab;
FIG. 5 is a vertical section through the assembled mold of FIG. 1 in the plane of the line 5--5 showing the mold template a molded slab and molded gel columns;
FIG. 6 is an enlarged view of a portion of the right end of FIG. 1 with parts broken away showing, with greater clarity, the sample wells molded integrally with the gel slab and with the template removed;
FIG. 7 shows the inside of an alternative top mold tray formed with lands and grooves; and,
FIG. 8 shows a top mold tray comprised of a number of piece parts for molding separate but contiguous horizontal thin slabs.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIGS. 1, 2 and 3 the reference numeral 11 designates an assembled gel mold for molding thin gel slabs ranging from 0.1 mm. to 3.0 mm. in thickness.
The assembly includes a bottom tray 12 having a planar platform defining a first mold surface or mold plate 13 surrounded by a base plane defined by flats 14, 16 and 17.
The bottom tray includes side walls 18 and 19 which cooperate with the sides 21, 22 and 23 of the platform to key or lock the mold assembly in proper position in a manner which will be more apparent as the specification proceeds.
Top tray 24 includes a second mold surface or mold plate 26 bounded by a skirt comprising skirt elements 27, 28 and 29. As is most apparent in FIGS. 1, 3 and 6, the top tray 24 is formed with a through slot 31 for receiving a template or mold core 32 having a plurality of tines 33--33 for molding deep sample wells 20 which communicate with and form extensions of shallow sample wells 25 molded in a thin gel slab 30. The through slot includes sidewalls 10 and 15 defining vertical mold plates.
As is most apparent in FIG. 4 the skirt elements 27, 28 and 29 of top tray 24, in the assembled condition of the mold trays, bear upon the base plane flats 14, 16 and 17 and in cooperation with the elevation of platform 13 establish the thickness dimension of a molded gel slab.
Usually the elevation of the platform, defining the first mold surface 13, is fixed and the thickness dimension of the molded slab is changed by changing the length L of the skirt elements depending from the top tray.
That is, one top tray 24 is formed with a skirt dimension that will produce a slab of a predetermined thickness and another top tray of a different skirt dimension produces a correspondingly different slab thickness.
When it is desired to mold a thin gel slab in combination with a deep sample well the bottom tray 12 is disposed in a suitable container or receptacle (not shown). Liquid gel material is deposited upon the mold surface 13 and the top tray 24 is assembled in the manner shown in FIGS. 1 and 4. Sufficient gel material is supplied so that in addition to molding a thin slab 30 excess gel extrudes into the elongated slot 31 filling the slot to mold a vertical slab between slot sidewalls or mold plates 10 and 15.
Next the template 32 is inserted into the gel filled slot and pressed "home" so that the tines 33--33 displace gel and bottom on the platform 13 (the first mold surface) as shown in FIG. 5.
Note that this occurrence creates shallow wells 25--25 (FIG. 6) in the gel slab 30 which are continuous with deep wells 20--20 formed by molded gel columns 34--34 and the internal side walls 10 and 15 of the slot 31. That is, the displacement of gel by the tines creates wells.
After the gel has "set" removal of the template 32 presents a sample well structure as shown in FIG. 6 in which a large volume sample well is available to complement a very small volume sample well in the thin gel slab.
Thus, in the practice of the principles of the present invention it is possible, using a template having tines of a given cross-sectional area, to mold large volume sample wells communicating with gel slabs ranging in thickness from 0.1 mm. to 3.0 mm. whose volume ranges from 5 to 100 times the volume of a well confined to the thin slab, per se.
FIG. 7 shows a modified top tray 38 having a plurality of lands 39 and grooves 41. This top tray is designed to mold a plurality of elongated gel slabs in the grooves 41. That is, when this top tray is assembled to the bottom tray 12 with an appropriate supply of gel compound, the lands 39 contact the mold surface 13 and the grooves mold a plurality of elongated individual thin gel slabs.
The grooves are formed in the top tray 38 so that the elongated molded gel slabs register with the tines 33 of the template to make certain that the deep sample wells formed by the template register with the slabs molded by the grooves.
FIG. 8 illustrates a top mold tray in the form of a plurality of separable piece parts for molding at least two adjoining gel slabs. The top tray 42 is shorter than top tray 24 of FIGS. 1, 2 and 3 and is complemented by a blank piece part 43 whose underside 44 makes face to face contact with mold surface 13 (FIG. 2) to block gel seepage and to establish a small mold cavity (first cavity) defined by the size of the top tray 42. After the gel in the first mold cavity has set, the blank 43 is removed and replaced by an additional top tray piece part 46 including a template and template slot.
That is, a new or different gel material is supplied to that portion of the first mold surface 13 which is exposed and an additional mold cavity (second mold cavity) formed by top tray part 46 adjoining the first gel is operable to mold a second different gel following the procedure previously described.
Upon insertion of the template 32, sample wells are molded in the same fashion as described previously with respect to the wells shown and described with respect to FIGS. 5 and 6.
Referring to FIGS. 1 and 6, it is noted that it is desirable to provide a dam or weir in the top tray in the region of the elongated slot 31 to provide a fluid path for buffer liquid to flow into the mouths or top openings of the sample wells and thence down the well into the gel slabs.
That is, the right side (FIG. 1) of the top tray 24, for example, is provided with a cut out or step 47 defining a weir or dam over which buffer liquid flows prior to entering the respective sample wells.
The said fluid path establishes electrical communication between the sample wells and the voltage source used to drive the sample species into and through the gels.
Note further that while the slot 31 and the mating template 32 are shown in a generally vertically position it is entirely within the spirit and scope of the invention to cant the slot and the template at an angle to the horizontal.
It is to be understood that the invention is not limited to the illustrations described and shown herein, which are deemed to be merely illustrative of the best modes of carrying out the invention, and which are susceptible of modification of form, size, arrangement of parts and details of operation. The invention rather is intended to encompass all such modifications which are within its spirit and scope as defined by the claims.
|
A method and apparatus is disclosed for molding thin gel slabs horizontally having deep, large volume sample wells molded integrally and in communication with the thin gel slab. The disclosure includes a method and apparatus for molding at least two contiguous thin gel slabs horizontally.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATIONS AND PATENTS
This application is a divisional of the commonly assigned, co-pending U.S. application Ser. No. 06/789,902, filed Oct. 10, 1985, and entitled "METHOD OF AND APPARATUS FOR PRODUCING A YARN" now U.S. Pat. No. 4,753,066, granted June 28, 1988, which, in turn, is related to the commonly assigned, U.S. application Ser. No. 06/734,845, filed May 15, 1985, and entitled "METHOD AND APPARATUS FOR PRODUCING A YARN", now U.S. Pat. No. 4,660,371, granted Apr. 28, 1987.
This application is related to the commonly assigned, co-pending U.S. application Ser. No. 07/155,956, filed Feb. 16, 1988, entitled "FRICTION SPUN YARN", now abandoned, application Ser. No. 07/167,029, filed Mar. 11, 1988, entitled "METHOD OF, AND APPARATUS FOR, PRODUCING A FRICTION SPUN YARN", now U.S. Pat. No. 4,773,209, granted Sept. 27, 1988.
BACKGROUND OF THE INVENTION
The present invention relates to a new and improved method of, and apparatus for, producing a yarn or the like.
In its more particular aspects, the present invention specifically relates to a new and improved method or producing a yarn or the like in which fibers are separated from a fiber strand and transferred to at least one friction spinning means at which a spun yarn is formed at least at one yarn forming position or location. During the step of forming the spun yarn, an air stream is drawn-in by suction through a perforated surface into the at least one friction spinning means and thereby the fibers are transferred to the perforated surface. The spun yarn thus formed is withdrawn in a predetermined withdrawal direction.
In a yarn spinning apparatus as known, for example, from Swiss Pat. No. 623,362 a device is provided for spinning a yarn according to the open-end friction-spinning principle. In accordance therewith, two perforated friction spinning drums which are maintained at sub-atmospheric pressure, spin a yarn from individualized fibers fed thereto in passages. The fibers are fed in respective passages to each spinning drum and in the direction of movement of the spinning drum, i.e. the fibers are delivered into both converging spaces. This has the disadvantage that the yarn forming position must be necessarily located at the narrowest place between the drums or rollers. As a result, the free space at this narrowest place is subjected to continuous variation due to the continually changing thickness of the yarn end located therein.
A further disadvantage of this apparatus is the necessity to perforate both friction spinning drums and subject both of the friction spinning drums to sub-atmospheric pressure or vacuum conditions in order to guide the fibers which are delivered onto the drums, to the yarn forming position or location in the related converging space.
Furthermore, such apparatus is very expensive and voluminous because of the delivery of fibers from both sides.
SUMMARY OF THE INVENTION
Therefore, with the foregoing in mind, it is a primary object of the present invention to provide a new and improved method of, and apparatus for, producing a yarn or the like and by means of which more than one fiber can be supplied per yarn formation in the simpleast possible manner.
Now in order to implement this and still further objects of the invention, which will become more readily apparent as the description proceeds, the yarn producing method of the present development is manifested by the features that, during the step of transferring the separated fibers to the at least one friction spinning means, the separated fibers are transferred at least at two fiber delivery locations in one predetermined or predeterminate direction to the friction spinning means.
According to more specific aspects of the invention, the method of producing a yarn or the like, comprises the steps of separating fibers from two fiber strands, wherein the separated fibers are transferred to two spacedly arranged friction spinning means each having a respective yarn forming location. The separated fibers may be transferred at different transfer rates to or towards related ones of the yarn forming locations. There is formed a friction spun yarn at the yarn forming locations of the two spacedly arranged friction spinning means.
The method may also be practiced such that the separated fibers are twisted in different twisting directions about yarn ends present at the related yarn forming location to thus form the friction spun yarn.
During the formation of the friction spun yarn, there is drawn in by suction an air stream through a respective perforated surface into each of the two spacedly arranged friction spinning means in order to thereby transfer the separated fibers to the perforated surfaces. The friction spun yarn is withdrawn in a predetermined yarn withdrawal direction, and during the step of transferring the separated fibers to the two spacedly arranged friction spinning means, there are transferred the separated fibers of the two fiber strands at least at two fiber delivery locations in a respective predetermined or predeterminate direction to each of the spacedly arranged friction spinning means.
As alluded to above, the invention is not only concerned with the aforementioned method aspects, but also relates to an improved construction of a yarn producing apparatus. Such apparatus, in its more specific aspects, contains at least two fiber separating means each of which contains a fiber delivery location for delivering fibers. There are further provided first friction spinning means and second friction spinning means which cooperate at a predetermined yarn forming location in order to form a spun yarn. Means are provided for generating an air stream which transfers the fibers from the fiber delivery location to a predetermined location at the first friction spinning means and at the second friction spinning means. The first friction spinning means and the second friction spinning means transport the fibers to the predetermined yarn forming location. Withdrawal means are provided for withdrawing the spun yarn in a predetermined yarn withdrawal direction.
According to the invention, the at lest two fiber separating means are arranged such that the fiber delivery locations are series-arranged with respect to the predetermined yarn withdrawal direction and that the fibers are delivered to the first friction spinning means at the predetermined location thereof.
In accordance with a particular construction of the apparatus for producing a yarn or the like the first friction spinning means and the second friction spinning means each constitute a friction spinning drum defining an axis. The first friction spinning drum and the second friction spinning drum are arranged with substantially parallel axes and in a nearly contacting relationship. The first friction spinning drum constitutes a perforated suction drum defining the perforated surface and containing a suction duct. The suction duct constitutes means for generating the air stream. Each one of the two friction spinning drums is sub-divided and forms related friction spinning drum sections. The friction spinning drum sections define pairs of cooperating friction spinning drum sections, and a related one of the fiber delivery locations are provided for each one of the pairs of the cooperating friction spinning drum sections.
It is one important advantage of the inventive method and apparatus that even for producing coarse yarns, e.g. of a count smaller than Ne 16, separation of the fiber sliver or strand which is fed to the separating or opening device or means, can be effected and enables individualization of the fibers prior to their deposition on the friction spinning device or means in a manner which is advantageous for the spinning process.
It is a further significant advantage of the inventive method and apparatus that, due to the series-arrangement of the fiber take-up positions as viewed from the yarn end, there exists the possibility of producing a friction spun yarn in which, for example, fibers of shorter staple length are located in the interior and fibers of greater staple length are located at the periphery of the yarn. In such a yarn, the fibers of greater staple length may also have a larger angle of inclination than the fibers of shorter staple length or vice versa. Furthermore, synthetic fibers can be located in the interior and natural fibers at the periphery of such friction spun yarn. Also, effect yarns can be produced in this manner.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein throughout the various figures of the drawings there have been generally used the same reference characters to denote the same or analogous components and wherein:
FIG. 1 is a partial and schematic, longitudinal view of a first exemplary embodiment of the apparatus according to the invention;
FIG. 2 is a side view in the direction I of a part of the apparatus shown in FIG. 1;
FIG. 3 is a view similar to FIG. 1 and shows a second exemplary embodiment of the inventive apparatus;
FIG. 4 is a side view in the direction II of a part of the apparatus shown in FIG. 3;
FIG. 5 is a view similar to FIG. 1 and shows a third exemplary embodiment of the inventive apparatus;
FIG. 6 is a plan view of the apparatus shown in FIG. 5;
FIG. 7 is a schematic illustration of a fourth exemplary embodiment of the apparatus according to the invention;
FIG. 8 is a partial plan view of the apparatus shown in FIG. 7;
FIG. 9 shows a section along the line III--III in FIG. 7;
FIG. 10 is a view similar to FIG. 1 of a fifth exemplary embodiment of the apparatus according to the invention;
FIG. 11 is a partial side view in the direction IV of the apparatus shown in FIG. 10;
FIG. 12 is a view similar to FIG. 7 of a sixth exemplary embodiment of the apparatus according to the invention;
FIG. 13 is a partial plan view of the apparatus shown in FIG. 12;
FIG. 14 is a view similar to FIG. 1 of a seventh exemplary embodiment of the apparatus according to the invention;
FIG. 15 illustrates a modification of the apparatus shown in FIG. 14;
FIG. 16 is a view in the direction V in FIG. 17 of an eighth embodiment of the inventive apparatus;
FIG. 17 is a view similar to FIG. 1 and in the direction VI in FIG. 16 of the apparatus shown in FIG. 16; and
FIG. 18 shows a partial plan view of the apparatus shown in FIG. 17.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, it is to be understood that only enough of the construction of the apparatus for producing a yarn or the like has been shown as is needed for those skilled in the art to readily understand the underlying principles and concepts of this invention, while simplifying the showing of the drawings. Turning attention now specifically to FIG. 1, there is schematically and partially illustrated in a longitudinal view a first exemplary embodiment of the inventive yarn producing apparatus containing two separating or opening means or assemblies 1 and 2 which operate according to the known rotor open-end spinning method. Respective fiber slivers or strands 3 and 4 are fed to the separating or opening means 1 and 2. For this feeding operation, respective feed shoes 5 and 6 and respective feed rolls 7 and 8 are used. These elements are known as such and are commonly referred to as fiber feed elements.
The separating or opening means or assemblies 1 and 2 each comprise a separating or opening roll (not shown) provided with needles or teeth which respectively extract or separate fibers from the slivers or strands 3 and 4 and transfer the separated fibers to related fiber feed or transport passages 9 and 10 connected with the separating or opening means or assemblies 1 and 2. The separating or opening means or assemblies 1 and 2 are arranged in juxtaposed relationship as seen in the direction of the axes of rotation of their separating or opening rolls.
At related exit openings or ports 11 and 12 of the fiber feed or transport passages 9 and 10, the separated fibers 13 are delivered or transferred in a disposition which is indicated by the reference numeral 13.1, to the surface of first friction spinning means constituting a first friction spinning drum 14 which is known as such and the surface of which moves in the direction of the arrow U. The exit openings 11 and 12 of the fiber feed or transport passages 9 and 10 in the presently described embodiment of the inventive apparatus as well as corresponding exit openings or exit ports present in other embodiments described hereinafter, constitute or define related fiber delivery locations at which the separated fibers are transferred in one predetermined direction to the friction spinning means, i.e. to the first friction spinning drum 14 at predetermined locations or take-up locations thereof, during the operation of such apparatus.
This first friction spinning drum 14 is suitably perforated (not shown) and is provided in its interior with a suction duct 15, see FIG. 2, which is known as such and which constitutes means for generating an air stream connected with a connector 16 and a source of sub-atmospheric pressure or vacuum (not shown). By means of this suction duct 15, air is drawn-in through the perforated first spinning drum 14 in a region S defined by duct walls 15a and 15b. An air stream or transporting air stream for the pneumatic fiber transfer or transport is thus drawn by suction through the pneumatic fiber feed or transport passages 9 and 10 and results in the fiber disposition designated 13.1. The separated fibers 13 are transferred or transported by the air stream to the friction spinning drum surface in a freely floating manner and are held at this surface by the drawn-in air. They are further transported to a yarn end 17 which is located at a predetermined yarn forming position or location 18. As a result, these fibers are taken up by the yarn end 17 and can be twisted to this yarn end.
A spun yarn or more specifically a friction spun yarn 19 thus is formed and withdrawn by withdrawal rolls 20 in a predetermined yarn withdrawal direction G. It is also to be noted from the showing of FIG. 1, for instance, that the separated fibers are transferred through the two separate fiber delivery locations defined by the exit openings or ports 11 and 12 in directions each having a direction component which is directed opposite to the yarn withdrawal direction G.
FIG. 2 does not shown the fiber feeding elements 5, 6, 7 and 8 and the fiber slivers or strands 3 and 4 but only shows openings 121 and 22 which are merely schematically indicated in FIG. 1 and respectively receive the fiber slivers or strands 3 and 4 at the separating or opening means or assemblies 1 and 2. This FIG. 2 shows second friction spinning means constituting a second friction spinning drum 23 which is known as such and which cooperates with the first friction spinning drum 14. This second friction spinning drum 23 may also be perforated and can be provided with a known suction duct 24. The first and second friction spinning drums 14 and 23 are arranged with parallel axes and in a nearly contacting relationship.
The friction spinning drums 14 and 23 are each rotatably and driveably arranged in known manner which is indicated in FIG. 1 by a dash-dotted line M and in FIG. 2 by respective crosses M and N. The rotatability and the driveability of the non-illustrated separating or opening rolls of the separating or opening means or assemblies 1 and 2 and of the feed rolls 7 and 8 and the withdrawal rolls 20 is also known as such, and is indicated hereinafter either by a respective cross and the designation K or by means of a dash-dotted line representing an axis with the designation K. The friction spinning means may be driven at a speed which exceeds the feed rate of the fibers to be transferred.
In FIG. 1 there is further illustrated by dotted or dash-dotted lines that the fiber feed or transport passages 9 and 10 can be provided at different or differently selected by equal inclinations relative to the predetermined or take-up location at the first friction spinning drum 14. This inclination is indicated by an angle α. The lengths L of their exit openings are constant. The fibers are delivered to the perforated surface of the first friction spinning drum 14 such that the fibers 13 lie upon the perforated surface in a substantially straightened disposition at a predetermined rearward inclination angle γ as seen in the predetermined yarn withdrawal direction G and are transferred to the predetermined yarn forming position or location 18 in such disposition. Under predetermined conditions taking into account the speed of movement in the direction U and the speed of the air or the fibers 13 in the region of the opening, the inclination of the fiber disposition 13.1 can be changed conjointly with the inclination angle α of the fiber feed or transport passages 9 and 10. The inclination of the fibers can be changed in such a manner that with decreasing angle α also the angle γ becomes smaller. During manufacture of the yarn it is possible to produce, for example, the following different yarn types on the basis of such variations in the angle γ of the fiber disposition 13.1 as well as on the basis of the illustrated double-feed and of the variants shown in FIGS. 14 to 18 still to be described hereinafter:
(i) A yarn comprising at least two substantially different staple lengths and in which the fibers of shorter staple length are provided in the interior and the fibers of greater staple length in the exterior region of the yarn cross-section.
(ii) A yarn which contains, in the inner region of its cross-section, synthetic fibers and natural fibers in the outer region.
(iii) Furthermore, a yarn in which the fibers in the inner region have a different angle of inclination or twist angle as compared to the fibers in the exterior region.
(iv) An effect yarn by periodic interruption of the delivery of the external fibers.
FIGS. 3 and 4 illustrate in views similar to FIGS. 1 and 2, a second exemplary embodiment of the inventive yarn producing apparatus which constitutes a variant of the apparatus illustrated in FIGS. 1 and 2. The difference is that the separating or opening means or assemblies 1 and 2 are arranged offset with respect to each other as viewed in the axial direction of the first friction spinning drum 14. As a result, the fiber slivers or strands 3 and 4 can be respectively applied substantially at the same height to the separating or opening means or assemblies 1 and 2.
In order to nevertheless series-arrange the exit openings 11 and 12 of the fiber feed or transport passages in this variant as viewed in the axial direction of the first friction spinning drum 14, these fiber feed or transport passages must be arranged inclined relative to each other in the manner illustrated in FIG. 4. The fiber feed or transport passage associated with the separating or opening means or assembly 1 is inclined to the right as viewed in FIG. 4 and designated by the reference numeral 9.1. The fiber feed or transport passage associated with the separating or opening means or assembly 2 is correspondingly inclined to the left and designated by the reference numeral 10.1.
In a non-illustrated variant of the apparatus shown in FIG. 4, the fiber feed or transport passages can be arranged without relative inclination in the manner illustrated in FIG. 2, so that the exit openings are arranged in a spaced relationship as viewed in axial direction of the first friction spinning drum. In such a variant, the feed or transport distance of the fibers delivered by the separating or opening means or assembly 1 to the first friction spinning drum 14 is positively greater than that of the fibers delivered by the separating or opening means or assembly 2.
FIGS. 5 and 6 illustrate a third exemplary embodiment of the inventive yarn producing apparatus which constitutes a second variant of the apparatus shown in FIGS. 1 and 2. In this variant, the separating or opening rolls or the assembled separating or opening means or assemblies 1 and 2 are coaxially arranged as seen in the direction of the axes of rotation of the separating or opening rolls.
Correspondingly, the fiber feed or transport passages designated by the reference numeral s9.2 and 10.2, are offset and arranged at an inclination relative to each other or at different inclinations relative to the predetermined or take-up location at the first friction spinning drum 14. Consequently, the exit openings or ports 11 and 12 are series arranged as viewed in the axial direction of the first friction spinning drum 14. The remaining elements shown in these Figures correspond to those of the apparatus shown in FIGS. 1 and 2.
For the sake of simplicity, the withdrawal rolls 20 and the spun yarn 19 have not been shown in FIG. 6.
As described with reference to FIG. 4, in a variant (not shown) the fiber feed or transport passages can be arranged without relative inclination, so that the exit openings or ports are arranged in a spaced relationship as viewed in the axial direction of the first friction spinning drum.
FIG. 7 shows a fourth exemplary embodiment of the inventive yarn producing apparatus in which the first friction spinning means constitutes a friction spinning disc 50 and the second friction spinning means constitutes a conical, specifically a frusto-conical roll 51.
The friction spinning disc 50 is appropriately perforated (not shown) and is supported for rotation and driven in a direction Q by means of a shaft 52. Furthermore, the frusto-conical roll 51 has a closed exterior surface and is supported for rotation and driven in a direction R by means of a shaft 53.
Two fiber feed or transport passages 54 and 55, of which only the passage 55 is shown in FIG. 7, are respectively connected with separating or opening means or assemblies 1 and 2 which are not illustrated in FIGS. 7 to 9 and which are of the type as described hereinbefore. Each of the passages 54 and 55 extends with its related exit opening 56 and 57 which are indicated by dash-dotted lines in FIG. 8, to the surface of the friction spinning disc 50 at a spacing H therefrom. As indicated by an angle β in FIG. 7, the fiber feed or transport passages 54 and 55 are arranged in a rearwardly inclined disposition as viewed in the direction Q, above the friction spinning disc 50. The angle β is formed by an imaginary plane of symmetry E defined by the fiber feed or transport passages 54 and 55 and the surface of the friction spinning disc 50.
A suction duct 58 is provided on the underside of the friction spinning disc 50 as viewed in the direction of the view of FIG. 7 or on a side which is remote from the frusto-conical roll 51. The fibers are delivered from the exit openings 56 and 57 to the friction spinning disc 50 as a result of the air flowing through the disc, and are transported on the disc which is moving in the direction Q to a predetermined yarn forming position or location 59 which is located in the converging space between the frusto-conical roll 51 and the friction spinning disc 50. At this yarn forming position or location 59, the fibers are twisted to form the spun yarn 19 which is withdrawn by means of the withdrawal rolls 20.
The suction passage 58 is connected with a suitable source (not shown) of sub-atmospheric pressure or vacuum by means of a connection tube 61.
In the apparatus embodiments described hereinbefore, the separated fibers which are delivered by the separating or opening means or assemblies, are pneumatically passed-on along a predetermined travel path to the first friction spinning means by means of the fiber feed or transport passages. In the further exemplary embodiments of the inventive yarn producing apparatus still to be described with reference to FIGS. 10 to 13, the fibers are, however, grasped already at their leading portions or sections by the first friction spinning means while the trailing portions or sections of the separated fibers are still held by the needles or teeth of the separating or opening rolls. Accordingly, the fibers thus never freely float throughout the entire process. The fibers are substantially mechanically guided along their travel path from the fiber slivers or strands 3 and 4 to their take-up at the first friction spinning means.
In the fifth exemplary embodiment shown in FIGS. 10 and 11, two opening devices 1 and 2 are provided immediately above the first friction spinning drum 14 and in series as viewed in the axial direction of the first friction spinning drum 14 such that the rotational axes K of the separating or opening rolls (not shown) are arranged parallel to each other.
Exit openings or ports 70 and 71 are respectively provided at the separating or opening means or assemblies 1 and 2 and form a fiber and air conducting connecting element between the separating or opening means or assemblies 1 and 2 and the first friction spinning drum 14. In this first friction spinning drum 14, a suction duct 15.1 is provided in a manner analogous to the embodiments described hereinbefore with reference to FIGS. 1 through 6. The duct 15.1 has walls 15.1a and 15.1b and thereby defines a suction zone S.1 at the first friction spinning drum 14 upon which the fibers are transported to the yarn end 17 at the yarn forming position or location 18.
As already described hereinbefore, the second friction spinning drum 23 can be provided with a suction duct 24 which is illustrated by dash-dotted lines in FIG. 11, provided that the second friction spinning drum 23 is also perforated. In the absence of this suction duct 24, the second friction spinning drum 23 has a continuous outer surface.
This suction duct 15.1 is connected with a non-illustrated source of sub-atmospheric pressure or vacuum by means of a suction port 16.
FIGS. 12 and 13 show a sixth exemplary embodiment of the inventive yarn producing apparatus in which, in comparison to the apparatus shown in FIGS. 7 to 9 and instead of the fiber feed or transport passages 54 and 55, the separating or opening means or assemblies 1 and 2 are arranged directly above the surface of the friction spinning disc 50. Exit ports 80 and 81 respectively form exit openings of the separating or opening means or assemblies 1 and 2 directed to the surface of the friction spinning disc 50. The spacing between the exit ports 80 and 81 and the friction disc 50 amounts to a maximum of 1 mm and is designated by the reference character H.
The remaining elements correspond to those of the apparatus described hereinbefore with reference to FIGS. 7 to 9.
For simplicity in the illustration, of the fiber sliver or strand feed elements which comprise the feed rollers 7 and 8 and the feed shoes 5 and 6, only the feed openings 21 and 22 of the separating or opening means or assemblies 1 and 2 have been illustrated.
In operation, the friction spinning disc 50 has in the suction region of the suction duct 58.1, a surface speed which is the same as or which is slightly greater than the peripheral speed of the separating or opening rolls (not shown) of the separating or opening means or assemblies 1 and 2. As a result, the fibers substantially assume a disposition designated by reference numeral 13.2 in FIG. 13 and are fed in this disposition to the yarn forming position or location 59.
The axes K of the separating or opening rolls of the separating or opening means or assemblies 1 and 2 do not necessarily have to extend in radial direction; as indicated by dash-dotted lines in FIG. 13, these axes may also be arranged in a staggered relationship.
The conicity of the frusto-conical roll 51 is adapted to the radial decrease in the surface speed of the friction spinning disc 50 such that the peripheral speed of the frusto-conical roll 51 corresponds to this surface speed.
The spun yarn 19 which is formed at the yarn forming position or location 59 in the converging space between the frusto-conical roll 51 and the surface of the friction spinning disc 50, is withdrawn by the withdrawal roll pair 20.
Furthermore, FIG. 14 shows a seventh exemplary embodiment of the inventive yarn producing apparatus. In this variant of the apparatus shown in FIGS. 1 and 2, the first and second friction spinning drums are each divided into two friction spinning drum sections which are rotatable and driveable independently from each other. In FIG. 14 only two friction spinning drum sections 90 and 91 are shown. There are formed pairs of cooperating first and second friction spinning drum sections and a fiber delivery location is provided at each such pair.
Furthermore, the spaced tandemly arranged friction spinning drum sections 90 and 91 are each equipped in their interior with a respective suction duct (not shown) which operates in a manner similar to the duct 15 illustrated in FIG. 2. Likewise and as described and illustrated with reference to FIGS. 1 and 2, the spaced tandemly arranged friction spinning drum sections which are not illustrated in FIG. 14 and which cooperate with the friction spinning drum sections 90 and 91, can be perforated and each equipped with a suction duct operating in a manner corresponding to the suction duct 24 shown in FIG. 2.
The drives or drive means for the friction spinning drum sections 90 and 91 and the axial intermediate space between such sections 90 and 91, are constructed such that the aforementioned suction ducts can be connected with not particularly shown sources of sub-atmospheric pressure or vacuum.
The remaining elements correspond to those of the apparatus shown in FIGS. 1 and 2.
During operation of the apparatus shown in FIG. 14, the separating or opening means or assembly 1 feeds fibers by means of the fiber feed or transport passage 9 to the friction spinning drum section 90 located closer to the withdrawal rolls 20. The separating or opening means or assembly 2 feeds fibers by means of the fiber feed or transport passage 10 to the friction spinning drum section 91 located farther from the withdrawal rolls 20.
Due to the independent drives and suction ducts of the friction spinning drum sections 90 and 91, there is the possibility of rotating the pairs of cooperating friction spinning drum sections with different rotational speeds and of subjecting the same to different sub-atmospheric pressures or vacuums. Depending upon the conditions, the fibers in the interior and the fibers in the exterior region of the cross-section of the spun yarn 19 can be provided with different twists, since not only the rotational speed of the friction spinning drum sections 90 and 91 but also the sub-atmospheric pressure or vacuum in their interiors is determinant for imparting the twist to the fibers at the yarn end. Furthermore, the width of the converging space formed by the two pairs of friction drum sections can be made variable and adjustable.
During build-up of the yarn, the fibers on the more distant friction spinning drum section 91 form the inner yarn region at a yarn forming position or location 93. The fibers on the closer friction spinning drum section 90 form the outer yarn region at the yarn forming position or location 92.
A modification of the apparatus illustrating in FIG. 14 is shown in FIG. 15. In this modification, the pair of friction drum sections more distant from the withdrawal rolls 20 and of which in FIG. 15 only the friction spinning drum 91 is shown, is upwardly displaced or offset as viewed in the direction of viewing FIG. 15 in an axially parallel manner. As a result, the yarn portion produced at the associated yarn forming position or location 93, is drawn over the drum edges of which in FIG. 15, only the drum edge 100 of the friction spinning drum section 91 is shown. During withdrawal in the yarn withdrawal direction G.
A yarn guide element 95 can be provided between the two friction spinning drum section pairs in order to avoid even a partial lifting-off of this yarn portion toward the adjacent friction spinning drum sections as viewed in the yarn withdrawal direction G. In FIG. 15, only the friction spinning drum section 90 is shown.
The remaining elements correspond to the elements of the apparatus illustrated in FIG. 14.
By means of this "drawing over the drum edges" operation, an increase in the yarn tension is produced in the yarn portion between the withdrawal roll pair 20 and the more distant friction spinning drum section pair, which is desirable for the strengthening of the yarn structure. It will be understood, however, that such an arrangement is suitable only for fiber blends which can resist tearing of the yarn portion immediately after the drum edge 100 as viewed in the yarn withdrawal direction G. The suitability of such a yarn blend must therefore be established from case to case.
If desired, and in a further, non-illustrated variant, the more distant friction spinning drum section pair can be arranged lower than the closer friction spinning drum section pair as viewed in the direction of viewing FIG. 15. As a result, a braking effect arises at the front drum edges, as viewed in the yarn withdrawal direction G, at the drum section pair located closer to the withdrawal roll pair 20. In this manner, the yarn portion formed at the more distant yarn forming position or location 93 is not additionally loaded in the yarn withdrawal direction.
Furthermore, it will be understood that the aforementioned "drawing over the drum edges" operation can be carried out not only by means of the two aforementioned apparatuses. It is quite possible to offset the two drum pairs relative to each other in various other, non-illustrated fashions so that one of the two aforementioned braking effects arises. The rotational axes K of the drum section pairs must not always be arranged parallel to each other.
An eighth embodiment of the inventive yarn producing apparatus is illustrated in FIGS. 16 to 18 and produces a yarn in which the fibers located in the inner region have a twist direction which is opposite to the twist direction of the fibers located in the outer region of the yarn.
Apart from additional members, to be described hereinafter, the apparatus comprises components which were already described hereinbefore with reference to FIG. 14.
In addition to such components already described with reference to FIG. 14, there is shown in FIG. 18 a further friction spinning drum section 96 which cooperates with the friction spinning drum section 90, located closer to the withdrawal roll pair 20, and a further friction spinning drum section 97 which cooperates with the friction spinning drum section 91 located more distant from the withdrawal roll pair 20. Drive N' and N" are provided for respectively driving the drum sections 90 and 91.
It is further evident from FIGS. 16 and 18 that the direction of rotation P of the "closer located" friction spinning drum sections 90 and 96 is opposed to the direction of rotation T of the "more distant" friction spinning drum sections 91 and 97. Correspondingly and since the fiber feed or transport passages 9 and 10 always open toward the friction spinning drum sections 90 and 91 which transport the fibers into the related converging spaces, the related exit openings or ports 98 and 99 are arranged offset relative to each other as viewed in the direction of viewing FIG. 18. The fiber feed or transport passage directed towards the "closer located" friction spinning drum section 90 is designated by the reference numeral 9.3 and its exit opening or port by the reference numeral 98. The fiber feed or transport passage opening towards the "more distant" friction spinning drum section 91 is designated by the reference numeral 10.3 and its exit opening or port by the reference numeral 99.
Due to the aforementioned opposite rotational directions, the fibers which are delivered or supplied to the yarn forming positions are locations 92 and 93, are twisted into the spun yarn 19 in opposite twist directions.
A yarn produced in this manner exhibits no, or only a small snarling tendency.
The number of fibers in the inner and outer regions of the yarn can be varied by means of a variable fiber feed or transport arrangement.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced without the scope of the following claims. Accordingly,
|
The method of, and apparatus for, producing a yarn uses a friction spinning device comprising a perforated first friction spinning drum and a second friction spinning drum which can also be perforated. Two fiber feed passages project to the first friction spinning drum and are each supplied by opening assemblies which individualize or individually separate the fibers. The fibers are transported toward the first friction spinning drum using a feed air stream in the fiber feed passages. This feed air stream is produced by the first friction spinning drum which is maintained under sub-pressure. Advantageously, the fiber double-feed to the friction spinning drum permits supplying two different fiber types to the same yarn end. Also, different inclinations of the fibers at the friction spinning drum can be obtained by different inclinations of the fiber feed passages in order to produce yarns of different character. The first and second friction spinning drums can be each divided into cooperating drum sections to define a first pair of coacting drum sections and spaced therefrom a second pair of coacting drum sections. The respective pairs of drum sections can be operated at different rotational speeds and can be subjected to different vacuum conditions.
| 3
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to long-term fertilizers containing nitrogen, methods for their production, and their use.
[0003] 2. The Prior Art
[0004] Fertilizers with a long-term effect have many advantages as compared with conventional mineral or organic fertilizers. They offer a delivery of the nutrients to the plants that is better in keeping with demand, and thereby improve the utilization of the nutrients. This results in a reduction of nutrient losses, thereby reducing the burden on the environment and increasing the efficiency of fertilization. In addition, they make it possible to save work steps and thereby to reduce agriculture business costs.
[0005] A long-term effect of fertilizers can be achieved in different ways. One possibility is to surround granulated fertilizers that are easily soluble in water with a coating that is insoluble in water. Nutrient release from such coated fertilizers takes place with a time delay, since the nutrients first have to diffuse through the coating layer, before they can be taken up by the roots. Another possibility is to apply the fertilizers initially in the form of chemical compounds in which they are not available to the plants. Only after a prior release step has taken place, e.g. chemical hydrolysis, enzymatic splitting and/or microbial conversion, are the nutrients present in a form that can be utilized by the plants. Such fertilizers are also referred to as chemical long-term fertilizers.
[0006] The idea of chemical long-term fertilizers was already known from the previous century. At that time, Liebig in Germany and Murray in England suggested using nutrients in the form of salts with low solubility for plant nutrition, see also Ullmann's Encyclopedia of Industrial chemistry 1987, Vol. A 10, p. 363 ff. The first patent for a long-term fertilizer with low solubility, on the basis of urea and formaldehyde, was filed in 1924 by IG Farben, today BASF (DRP 431585). Commercial production began in the fifties, in the United States, by DuPont and Nitroform Corp.
[0007] Today, a large number of substances that contain nitrogen are being produced and marketed as long-term fertilizers. The three most important ones, by far, are condensation products from urea and formaldehyde, isobutyraldehyde and acetaldehyde, respectively, which are referred to as methylene urea, isobutylidene diurea (IBDU), and crotonylidene diurea (CDU).
[0008] During the fertilization year 1995/1996, approximately 317,000 metric tons of such long-term fertilizers were produced, of which 225,000 metric tons were fertilizers containing methylene urea, 82,000 metric tons contained IBDU and CDU, and approximately 10,000 metric tons were fertilizers containing other compounds.
[0009] Among the substances produced on a smaller scale, there are both cyclic and acyclic structures. Here, oxamide, acetylene diurea, melamine, substituted triazones, ethylene diurea, and triuret are examples thereof.
[0010] These known long-term nitrogen fertilizers differ greatly, in some respects, in their duration of effect, in each instance. While the effect stops relatively rapidly in the case of substances with a shorter period of effect. This is because nitrogen deficiency symptoms frequently occur at the beginning of the culture time in the case of N fertilization solely with compounds with a longer period of effect, since the mineralization from these materials often takes place only after a delay. In addition, not all of these compounds are tolerated by plants without restrictions, and instead result in plant damage, depending on the amount used and the culture being fertilized.
SUMMARY OF THE INVENTION
[0011] It is therefore an object of the present invention to make available fertilizer formulations that are suitable as long-term N fertilizers and are superior to the known substances, preferably in the area of plant tolerance, period of effect, and uniformity of nutrient delivery.
[0012] This object is accomplished, according to the present invention, by means of a long-term fertilizer containing nitrogen, containing a mixture of acetylene diurea and at least one other organic fertilizer containing nitrogen.
[0013] It was found, according to the present invention, that the effect of acetylene diurea with other organic fertilizers containing nitrogen is derived not only additively from the property profiles of the individual components, but rather that synergistic effects are demonstrated, over and above this, which result in an unexpectedly strong and long-lasting support of plant growth.
[0014] The at least one other organic fertilizer containing nitrogen can be selected from among all the known suitable fertilizers of this type. Preferably, the at least one other organic fertilizer containing nitrogen is selected from among methylene urea, isobutylidene diurea, crotonylidene diurea, oxamide, melamine, substituted triazones, ethylene diurea, triuret or mixtures of these compounds.
[0015] Isobutylidene diurea is preferred as the at least one other organic fertilizer containing nitrogen.
[0016] Such organic fertilizers containing nitrogen are available, for example, from Scotts, Agra, BASF, Vigoro, and Chisso.
[0017] For a more detailed description, reference can be made to EP-A-0 578 240 for oxamide, to JP-A-62 288 184 for acetylene diurea, to U.S. Pat. No. 4,778,510 for substituted triazones, to JP-A-49 013 268 for ethylene diurea, and to JP-A-90 35 152 for triuret.
[0018] Acetylene diurea and other organic fertilizers containing nitrogen are preferably present in a weight ratio of 1:9 to 9:1, particularly preferably 1:3 to 3:1, particularly 3:2 to 2:3.
[0019] The long-term fertilizers according to the present invention can furthermore contain other components as they usually occur in single-nutrient and multi-nutrient fertilizers. For example, they can additionally contain urea or nitrogen, potassium, phosphorus and/or magnesium in the form of inorganic salts, or mixtures of them. Easily soluble nitrogen components are, for example, ammonium nitrate, ammonium sulfate, or urea. Other salts that can be used are, for example, MAP, DAP, potassium sulfate, potassium chloride, magnesium sulfate. These additional components can be the main components of the long-term fertilizer, in addition to the mixtures according to the invention. Furthermore, in addition to the main components, secondary nutrients can also be present. For example, secondary nutrients can be selected from among Ca, S, and B. Trace elements, selected from among Fe, Mn, Cu, Zn, Mo or mixtures of them, can also be present in the form of inorganic salts. Suitable amounts for the secondary nutrients or trace elements are amounts of 0.5 to 5 wt.-%, based upon the total weight of the long-term fertilizer composition. Other possible ingredients are plant protection agents, such as insecticides or fungicides, growth regulators, nitrification inhibitors, or mixtures of them.
[0020] Other possible ingredients of the fertilizers according to the invention are described in Ullmann's Encyclopedia of Industrial Chemistry, 5th edition, 1987, Volume A10, pages 363 to 401, DE-A-41 28 828, DE-A-19 05 834, or DE-A-196 31 764.
[0021] The long-term fertilizers according to the invention can also be coated, in whole or in part, as described in EP-A-0 877 722 or DE-A-196 31 764.
[0022] The long-term fertilizers containing nitrogen, according to the invention, can contain single-nutrient as well as multi-nutrient fertilizers as other usual fertilizer components, for example, which contain nutrients such as nitrogen, potassium, or phosphorus, individually or, if necessary, in combination, in the form of their salts. Examples of these are NP, NK, PK, as well as NPK fertilizers such as lime nitrate of ammonium, ammonia sulfate, ammonia sulfa-nitrate, or urea.
[0023] The long-term fertilizers according to the present invention can be obtained according to generally known methods. For example, they can be produced by means of mixing of powders or granules, i.e. granulates of the starting compounds and, if necessary, subsequent granulation. The production of fertilizer granulates is described, for example, in Ullmann's Encyclopedia of Industrial Chemistry, 5th edition, 1987, Volume A10, page 374 to 385.
[0024] The long-term fertilizers containing nitrogen, according to the present invention, can be used to fertilize a large number of plants or soils. Preferably, the long-term fertilizers are used to fertilize horticultural or agricultural cultures, particularly lawns or ornamental plants. In this connection, they are usually applied to areas used for agriculture or horticulture according to generally known methods, see also Ullmann's Encyclopedia of Industrial Chemistry, 5th edition, 1987, Volume A10, pages 398 to 401. Because of their high level of plant tolerance, the long-term fertilizers according to the present invention are suitable not only for fertilizing methods in which the fertilizer is applied to the agricultural area more or less uniformly, but also for targeted deposition in the vicinity of the plant root.
[0025] The long-term fertilizers according to the invention can fundamentally be used in all sectors of plant cultivation, such as agriculture and horticulture, for example in fruit and vegetable cultivation.
[0026] Examples of suitable cultures are ornamental plants, lawns, as well as cultures for consumption, such as apples, pears, strawberries, tomatoes, peppers, and others.
[0027] The long-term fertilizers according to the present invention are characterized in that they permit particularly efficient intensive use of areas used for agriculture and horticulture, whereby a burden on the environment is avoided to a great extent.
[0028] The long-term fertilizers according to the invention are applied to the areas used for agriculture or horticulture according to usual methods, or mixed into the substrate of pot or container cultures, or sprinkled on.
[0029] For optimum promotion of growth of the plants, it is generally sufficient to apply the long-term fertilizers according to the invention to the agricultural surface once per growth period (preferably at its beginning). This is because the progression of the nutrient demand of the plants and the progression of the release of the active fertilizer ingredients agree with one another.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0030] The invention will be explained in greater detail below, using examples.
EXAMPLES
[0031] To demonstrate the good and long-lasting effect of the formulations according to the invention, extensive agricultural experiments were conducted. Isobutylidene diurea (IBDH), acetylene diurea (ADH), ethylene diurea (EDH), and triuret were tested as the sole sources of long-term nitrogen, as were mixtures with IBDH in a ratio of 67%/33% (container experiments) and 60%/40% (field experiments). The fertilizers contained the other main and secondary ingredients, as well as some easily soluble nitrogen for an initial effect, in equal amounts.
[0032] The container experiments were carried out in Mitscherlich containers with Weidel grass as the test culture, and the grass was mowed at regular intervals, its dry mass was determined, and it was analyzed for its N content. The amount of N absorbed per mowing was calculated by means of both variables, addition results in the nitrogen utilization. The results are shown in Table 1. Table 1 makes it clear that when using IBDH+ADH in combination, the nitrogen utilization of fertilization is clearly higher than if one of the two long-term forms of nitrogen is administered alone. In this connection, the N utilization is 75%, while theoretically, the given shares of the long-term fertilizer components in each instance, result in a utilization of only 59%. The combinations of IBDH with other forms of nitrogen, without ADH, do not demonstrate these advantages.
TABLE 1 Nitrogen utilization by means of different long-term fertilizer combinations (% nitrogen in leaves of Weidel grass in relation to the amount of nitrogen applied, in total; Mitscherlich containers; 5 L soil; 2.4 g/container N; 9 mowings; 23 to 207 days after fertilization) N N utilization utilization %, %, predicted Long-term fertilizer compound measured value proportion (real) (calculated) 100% IBDH-N 54 — 100% ADH-N 70 — 67% + 33% IBDH + ADH-N 75 59 100% EDH-N 68 — 67% + 33% IBDHN + EDH-N 56 58 100% Triuret-N 38 — 67% + 33% IBDH N + Triuret-N 50 48 100% CDU-N 58 — 67% + 33% IBDH N + CDU-N 54 55
[0033] In addition to container experiments, the fertilizer combination was also tested in field experiments on lawns, a main area of use of slow-acting nitrogen forms. The assessment criteria in this connection are the color appearance for the optical quality, as well as the growth height as a measure of the regeneration strength of the sod. The fertilizers were applied once, in an application amount of 20 g/m 2 N. The results are summarized in Tables 2 and 3. The figures in Tables 2 and 3 show that both in terms of the color appearance and in terms of the growth height, values above expectations were achieved with the combination of IBDH and ADH.
[0034] Thus, the real assessment marks for color appearance in Table 2, other than at the time of 124 days after fertilization, were clearly above the calculated predicted value. Here again, it was evident that the synergistic effects did not occur with the other combinations of long-term fertilizer forms. A comparable picture is given by Table 3 with regard to the growth heights of the sod (Table 3).
[0035] Accordingly, while a few embodiments of the present invention have been shown and described, it is to be understood that many changes and modifications may be made thereunto without departing from the spirit and scope of the invention as defined in the appended claims.
TABLE 2 Appearance of lawns when using different long-term nitrogen fertilizer combinations (Appearance assessment 1-9, 9 = dark-green dense sod; fertilization on March 21, 2000, with 20 g/m 2 N; assessment every two weeks) Days after fertilization 27 40 54 66 81 109 124 139 153 166 173 187 AVG. 100% IBDH-N 8,10 7,90 6,80 5,40 4,50 5,00 4,90 5,30 5,30 4,50 4,30 3,80 5,48 100% ADH-N 6,10 7,50 8,50 8,00 8,40 7,10 6,10 5,60 5,60 5,00 4,40 3,90 6,35 50% IBDH + 50% 7,50 8,00 8,00 7,00 6,60 6,40 5,50 5,80 5,60 5,00 4,50 3,90 6,15 ADH-N Predicted value 7,10 7,70 7,65 6,70 6,45 6,05 5,50 5,45 5,45 4,75 4,35 3,85 5,92 Deviation as compared 0,40 0,30 0,35 0,30 0,15 0,35 0,00 0,35 0,15 0,25 0,15 0,05 0,23 with predicted value 100% IBDH-N 8,10 7,90 6,80 5,40 4,50 5,00 4,90 5,30 5,30 4,50 4,30 3,80 5,48 100% EDH-N 6,90 5,80 5,80 5,30 5,60 7,40 5,80 5,90 5,80 5,00 4,60 3,90 5,65 50% IBDH + 50% 7,40 6,80 6,10 5,40 5,00 6,20 5,40 5,50 5,40 4,60 4,00 3,50 5,44 EDH-N Predicted value 7,50 6,85 6,30 5,35 5,05 6,20 5,35 5,60 5,55 4,75 4,45 3,85 5,57 Deviation as compared −0,10 −0,05 −0,20 0,05 −0,05 0,00 0,05 −0,10 −0,15 −0,15 −0,45 −0,35 −0,13 with predicted value 100% IBDH-N 8,10 7,90 6,80 5,40 5,10 5,00 5,20 5,30 5,30 4,50 4,30 3,80 5,56 100% Triuret-N 6,40 6,00 7,10 6,80 6,00 6,40 5,90 6,40 6,00 5,40 4,80 4,40 5,97 50% IBDH + 50% 7,30 6,80 6,70 6,20 5,60 5,60 5,50 5,90 5,30 5,00 4,50 4,00 5,70 Triuret-N Predicted value 7,25 6,95 6,95 6,10 5,55 5,70 5,55 5,85 5,65 4,95 4,55 4,10 5,76 Deviation as compared 0,05 −0,15 −0,25 0,10 0,05 −0,10 −0,05 0,05 −0,35 0,05 −0,05 −0,10 −0,06 with predicted value 100% IBDH-N 8,10 7,90 6,80 5,40 4,50 5,00 4,90 5,30 5,30 4,50 4,30 3,80 5,48 100% CDU-N 6,60 7,80 8,50 7,90 6,80 5,90 5,00 5,60 5,40 4,90 4,60 4,00 6,08 50% IBDH + 50% 7,40 7,90 7,50 6,60 5,10 5,30 5,00 5,50 5,30 4,60 4,30 3,90 5,70 CDU-N Predicted value 7,35 7,85 7,65 6,65 5,65 5,45 4,95 5,45 5,35 4,70 4,45 3,90 5,78 Deviation as compared 0,05 0,05 −0,15 −0,05 −0,55 −0,15 0,05 0,05 −0,05 −0,10 −0,15 0,00 −0,08 with predicted value
[0036] [0036] TABLE 3 Growth of lawns when using different long-term nitrogen fertilizer combinations over the course of the vegetation period (Fertilization on March 21, 2000, with 20 g/m 2 N; growth height measurement before every mowing in cm above soil surface; 1 mowing/week) Days after fertilization 21 27 35 43 49 57 64 70 77 86 91 98 106 113 100% IBDH-N 8,35 10,3 10,4 13,58 6,93 4,9 6,9 6,05 5,83 3,7 4,88 5,13 3,38 4,48 100% ADH-N 6,35 7,38 5,5 11,1 7,1 5,63 7,55 6,18 6,75 4,73 4,85 6,48 4,93 5,68 50% IBDH + 50% 7,45 8,9 8,43 12,8 7,43 5,72 7,73 6,68 6,58 4,4 5,28 5,95 4,15 5,25 ADH-N Predicted value 7,35 8,84 7,95 12,34 7,02 5,27 7,23 6,12 6,29 4,22 4,87 5,81 4,16 5,08 Deviation as compared 0,10 0,05 0,45 0,46 0,42 0,45 0,51 0,57 0,29 0,19 0,42 0,15 0,00 0,17 with predicted value 100% IBDH-N 8,35 10,3 10,4 13,58 6,93 4,9 6,9 6,05 5,83 3,7 4,88 5,13 3,38 4,48 100% EDH-N 7 8,3 5,95 9 5,65 4,08 6,53 6,05 5,73 4,45 6,5 6,55 4,8 6,05 50% IBDH + 50% 7,6 9,35 8,08 10,48 5,93 4,35 6,23 5,9 5,7 4,15 5,65 5,63 4,1 4,9 EDH-N Predicted value 7.68 9,30 8,18 11,29 6,29 4,49 6,72 6,05 5,78 4,08 5,69 5,84 4,09 5,27 Deviation as compared −0,08 0,05 −0,10 −0,81 −0,36 −0,14 −0,48 −0,15 −0,08 0,08 −0,04 −0,21 0,01 −0,37 th predicted value 100% IBDH-N 8,35 10,3 10,4 13,58 6,93 4,9 6,9 6,05 5,83 3,7 4,88 5,13 3,38 4,48 100% Triuret-N 6,83 7,93 6,3 9,43 5,85 4,33 6,95 6,13 6,05 4,18 5,38 5,6 4,13 5,35 50% IBDH + 50% 7,48 9,13 8,63 11,83 6,55 4,75 6,83 6,25 6,08 4,13 5,08 5,4 3,98 5,13 Triuret-N Predicted value 7,59 9,12 8,35 11,51 6,39 4,62 6,93 6,09 5,94 3,94 5,13 5,37 3,76 4,92 Deviation as compared 0,11 0,02 0,28 0,33 0,16 0,14 −0,10 0,16 0,14 0,19 −0,05 0,04 0,23 0,22 with predicted value 100% IBDH-N 8,35 10,3 10,4 12,58 6,93 4,9 6,9 6,05 5,83 3,7 4,88 5,13 3,38 4,48 100% CDU-N 6,93 8,08 6,9 12 7,3 5,93 8,43 7,03 6,98 4,58 5,43 5,35 3,85 4,95 50% IBDH + 50% 7,38 8,9 8,7 12,08 7,2 5,13 7,53 6,55 6,08 4 5,08 5,15 3,5 4,75 CDU-N Predicted value 7,64 9,19 8,65 1,29 7,12 5,42 7,67 6,64 6,41 4,14 5,16 5,24 3,62 4,72 Deviation as compared −0,26 −0,29 0,05 −0,21 0,09 −0,29 −0,14 0,01 −0,33 −0,14 −0,07 −0,09 −0,12 0,04 with predicted value Days after fertilization 120 127 134 141 147 155 161 169 176 183 190 196 AVG. 100% IBDH-N 4,93 4,4 4,68 4,88 4,15 4,93 4,53 4,18 4,13 3,68 4,25 4,18 5,68 100% ADH-N 6,08 5,3 5,35 5,7 4,58 5,38 4,85 4,43 4,33 4,13 4,65 4,33 5,74 50% IBDH + 50% 5,63 5,13 5,13 5,4 4,6 5,35 4,98 4,38 4,23 3,98 4,33 4,25 5,93 ADH-N Predicted value 5,51 4,85 5,02 5,29 4,37 5,16 4,69 4,31 4,23 3,91 4,45 4,26 5,71 Deviation as compared 0,13 0,28 0,12 0,11 0,23 0,20 0,29 0,08 0,00 0,07 −1,12 0,00 0,22 with predicted value 100% IBDH-N 4,93 4,4 4,68 4,88 4,15 4,93 4,53 4,18 4,13 3,68 4,25 4,18 5,68 100% EDH-N 6,23 5,35 5,6 5,53 4,43 5,48 4,98 4,38 4,38 4,05 4,28 4,33 5,60 50% IBDH + 50% 5,35 4,8 5 5,3 4,4 5,03 4,7 4,3 4,2 3,95 4,28 4,23 5,52 EDH-N Predicted value 5,58 4,88 5,14 5,21 4,76 4,28 4,26 3,87 4,27 4,26 5,64 Deviation as compared −0,23 −0,08 −0,14 0,09 0,11 −0,18 −0,06 0,02 −0,05 0,09 0,01 −0,02 −0,12 with predicted value 100% IBDH-N 4,93 4,4 4,68 4,88 4,15 4,93 4,53 4,18 4,13 3,68 4,25 4,18 5,68 100% Triuret-N 5,75 5,23 5,45 5,75 4,7 5,73 4,98 4,4 4,3 4,2 4,55 4,33 5,53 50% IBDH + 50% 5,53 5,05 5,08 5,45 4,68 5,13 4,7 4,3 4,15 4 4,3 4,28 5,69 Triuret-N Predicted value 5,34 4,82 5,07 5,32 4,43 5,33 4,76 4,29 4,22 3,94 4,40 4,26 5,61 Deviation as compared 0,19 0,23 0,02 0,14 0,25 −0,20 −0,06 0,01 −0,06 0,06 −0,10 0,03 0,08 with predicted value 100% IBDH-N 4,93 4,4 4,68 4,88 4,15 4,93 4,53 4,18 4,13 3,68 4,25 4,18 5,64 100% CDU-N 5,33 4,63 5,05 5,28 4,4 4,98 4,68 4,15 4,15 3,9 4,33 4,2 5,72 50% IBDH + 50% 5,3 4,58 4,98 5,13 4,5 4,93 4,55 4,13 4,13 3,78 4,28 4,15 5,63 CDU-N Predicted value 5,13 4,52 4,87 5,08 4,28 4,61 4,17 4,14 3,79 4,29 4,19 5,68 Deviation as compared 0,17 0,06 0,12 0,05 0,23 −0,03 −0,06 −0,04 −0,01 −0,01 −0,01 −0,04 −0,05 with predicted value
|
A long-term fertilizer containing nitrogen, contains a mixture of acetylene diurea and at least one other organic fertilizer containing nitrogen, such as methylene urea, isobutylidene diurea, crotonylidene diurea, oxamide, melamine, substituted triazones, ethylene diurea, triuret or mixtures of them.
| 2
|
CONTINUITY DATA
[0001] Priority is hereby claimed by provisional application 60/595,241 filed on Jun. 17, 2005.
Field of the Invention
[0002] The present invention relates generally to mining and specifically to remote mining of bedded mineral deposits.
BACKGROUND OF THE INVENTION
[0003] Known methods of remote mining in bedded mineral deposits such as coal seams employ a mining machine that excavates mine openings to some distance from the seam exposure on the surface and means of conveying are required to transport the excavated material to the surface. In most of the present systems, conveying machines consisting of multiple conveyors are advanced into the mine openings from the surface. For example, U.S. Pat. Nos. 5,112,111, 5,232,269 and 5,261,729 to Addington at al. disclose an assembly of conveyors and a mining machine advanced into the seam without interrupting the flow of aggregate material by separate means designed to pull at the forward end and push at the rearward end. Similarly, U.S. Pat. No. 5,609,397 to Marshall at al. discloses an assembly of conveyors interconnected with a mining machine and a driving device located outside the seam and consisting of rack and pinion or, alternately, reciprocating cylinders, linear tracks, linear or rotary drives, chains, cables or other mechanical devices. The U.S. Pat. 5,692,807 to Zimmerman discloses a guidance assembly for extending and retracting an assembly of conveyors in and out of the seam. The U.S. Pat. 3,497,055 to Oslakovic at al. discloses a multi-unit train of conveyors having a self-propelled unit at each end coupled to intermediate units, each end unit being capable of towing the intermediate units. The U.S. Pat. 2,826,402 to Alspaugh at al. discloses a train of wheeled conveyor sections pulled into the mine opening and pushed out of it by a self-propelled mining machine. Buckling of the train is avoided by the grooves made by the mining machine in the floor, said grooves spaced the same distance as the treads of the wheels carrying the conveyor sections. The U.S. Pat. 6,220,670 to Mraz discloses a train of self-propelled conveying units capable of advancing or retreating in the seam on its own power. The U.S. Pat. 5,299,674 to Cusitar discloses belt support cars for an extensible belt conveyor system which are connected by horizontally pivoting joints and being movable from tangential direction to an axial position for the support of the upper and the lower strands of the extensible conveyor.
[0004] In the present systems that utilize multi-unit trains of conveyors, the interconnected combination of the mining machine and a conveying assembly comprising a plurality of conveyors is advanced into the seam from a launch vehicle located on the outside. When the present mining hole is completed and the train of conveying units retreats from the seam, it is gradually disassembled and the mining machine is moved onto the launch. The launch with the mining machine then moves to the next mining hole. As the conveying assembly consists of a plurality of conveyor units, each of the individual conveyors requires a substantial headroom space for transfer of material from each conveyor unit to the next. This makes it impractical to design a belt conveyor system that would fit into seams that are less than 34 inches thick. It would be therefore desirable to utilize an endless extensible belt conveyor supported by belt support units. Such system would allow mining seams that are, at minimum, 24 inches thick or less. However, in the system proposed by Cusitar Pat. No. 5,299,674, the belt support cars would have to move to the side without entering the platform and the mining machine would have to move on its own power to the next mining hole on the highwall mining bench. The soft and muddy highwall mining bench would make such a system impractical in most mining environments. Even on exceptionally firm highwall mining bench, handling of the belt support car assembly and the mining machine on the highwall mining bench would require excessive time and manpower. Such arrangement would also require disconnecting and reconnecting the mining machine with the extensible belt conveyor, which would further reduce productivity of the operation. It would be therefore desirable to utilize an endless belt conveyor supported by belt support units that could be assembled and disassembled similarly as the present conveyor units. It would be also desirable to move the mining machine onto the launch utilizing an endless extensible belt conveyor and move the launch as required with the mining machine on it. And, it would be desirable for the mining machine to remain connected to the extensible belt conveyor at all times.
SUMMARY OF THE INVENTION
[0005] Accordingly, it is the object of the present invention to provide a method and apparatus for connecting the mining machine to the endless extensible belt conveyor without the need of disconnecting the belt from the mining machine during the repositioning of the highwall mining launch.
[0006] Another object of the present invention is to provide a method and apparatus for retreating or advancing the mining machine on the launch without disconnecting the belt from the mining machine.
[0007] Another object of the present invention is a method and apparatus of aligning the belt with the mining machine while retreating or advancing the mining machine on the launch and using the same apparatus for steering the mining machine while advancing the mining machine into the mining hole.
[0008] Another object of the present invention is a method and apparatus of adding and removing belt support on the launch.
[0009] Another object of the present invention is a method and apparatus of advancing the mining machine into and retrieving it from the mining hole.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a plan view of the highwall mining launch according to the preferred embodiment of the present invetion with the mining entering the mining hole.
[0011] FIG. 2 is a cross sectional view taken along the line A-A of FIG. 1 , with the mining machine located on the launch before it enters the mining hole.
[0012] FIG. 3 is a cross sectional view taken along the line A-A of FIG. 1 , with the mining machine located at the start of the mining hole.
[0013] FIG. 4 is a cross sectional view taken along the line A-A of FIG. 1 , with the mining machine located at the start of the mining hole and the first belt support structure unit inserted onto the launch.
[0014] FIG. 5 is a cross sectional view taken along the line A-A of FIG. 1 , with the mining machine located at the start of the mining hole and the first belt support structure unit connected to the mining machine.
[0015] FIG. 6 is a cross sectional view taken along the line A-A of FIG. 1 , with two belt support structure units connected to the mining machine.
[0016] FIG. 7 is a side view of the mining machine and the belt support structure units in the mining hole.
[0017] FIG. 8 is a side view of the belt support structure unit.
[0018] FIG. 9 is a view of the belt support structure taken along the line B-B of FIG. 8 with a cantilever support bracket in a closed position.
[0019] FIG. 10 is a view of the belt support structure taken along the line B-B of FIG. 8 with a cantilever support bracket in an open position.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Referring to FIGS. 1 through 7 , a highwall mining launch 1 operates in the vicinity of a highwall 2 containing a seam 3 on a highwall mining bench 4 . A mining machine 5 is advanced from the launch 1 into the seam 3 . The launch 1 includes the launch deck 6 , means of propel 7 , an assembly of belt storage magazines 8 , a hydraulic power unit 21 , an electrical substation 22 , a power cable winder 23 , a water hose winder 24 and a control cable winder 24 . An endless conveyor belt 8 is wound trough a belt drive 9 around deflection rollers 16 , 17 , 17 a and 17 b, through the belt storage unit assembly, around the tail roller 32 and through telescopic idlers 13 . The tail roller 32 is mounted within a tail piece 18 connected to the mining machine 5 with cylinders 19 . When a belt support unit 20 is inserted onto the lauch deck 6 , the upper belt 8 a runs over the telescopic idlers 13 and the lower belt 8 b runs through the belt support unit 20 .
[0021] When the mining machine 5 is retrieved from the seam 3 onto the launch 1 , the belt 8 remains wound around the tail roller 32 and the telescopic idlers 13 are contracted at the far end of the rail 14 . When the launch 1 moves to a new mining position, pusher plates 26 a on the tail piece 18 are engaged by pushers 25 connected to endless chains 27 engaged with the chain drive sprockets 28 and the tail sprockets 29 . The mining machine 5 is moved toward the highwall 2 and begins excavating in the seam 3 . The excavated material is transferred from the mining machine 5 into the tail unit 18 . As the mining machine 5 advances into the seam 3 , the telescopic idlers 13 are spaced along the path of the upper belt 8 a. The hydraulic cylinders 19 that connect the tail unit 18 with the mining machine 5 are actuated as required to steer the mining machine 5 .
[0022] When the mining machine 5 clears the launch deck 6 , the belt deflection roller 17 b is lifted and this lifts the lower belt 8 b to provide room for the insertion of the belt support unit 20 onto the launch deck 6 . After the belt support unit 20 is inserted onto the launch deck 6 , pusher bars 26 on the belt support unit 20 are engaged by pushers 25 connected to endless chains 27 engaged with the chain drive sprockets 28 and the tail sprockets 29 . The deflection roller 17 b is lowered to allow the passage of the belt support unit 20 , which is pushed toward the tail unit 18 and connected to the tail unit 18 with connectors 35 .
[0023] As the mining machine 5 is advanced into the mining hole 3 a within the seam 3 by forward motion of pushers 25 , the cylinders 19 connecting the tail unit 18 with the mining machine 5 are actuated as required to steer the mining machine 5 in the desired direction. The upper belt 8 a gradually settles onto the top of the belt support unit 20 .
[0024] When the mining machine 5 is advanced into the seam 3 by the length of one belt support unit, the belt deflection roller 17 b lifts the bottom belt 8 b, another belt support unit 20 is inserted onto the launch deck 6 and connected to the previous belt support unit 20 with the connectors 35 .
[0025] Referring to FIGS. 8 through 10 , the belt support unit 20 consists of the frame 20 a, the cantilever beams 20 b, main beams 20 c and support wheels 36 . The cantilever beams 20 b carry troughing belt idlers 33 and the frame 20 a carries return belt idlers 34 . The structural pockets 37 provide means for handling the belt support unit 20 with a fork lift or a front-end loader. During the insertion of the belt support unit 20 onto the launch deck 6 , the swingable support brackets 38 are lifted out of the way in order to insert the bottom belt 8 b between the frame 20 a and the cantilever beams 20 b and than re-engaged in order to support the upper cantilever beams 20 b during the operation. The upper belt 8 a is supported by the troughnig idlers 33 mounted on the cantilever beams 20 b and the lower belt 8 b is supported by the return idlers 34 .
[0026] The foregoing preferred specific embodiment has been shown and described for the purpose of illustrating the functional and structural principles of this invention and is subject to change without departure from such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims.
|
A remote mining system utilizes extensible belt conveyor supported by belt support units and is suitable for operation in very low mining seams. The launch platform contains sufficient storage of conveyor belt for deep penetration into a very low seam. The mining machine is retrieved onto the platform but remains connected to the extensible belt conveyor at all times.
| 4
|
BACKGROUND OF THE DISCLOSURE
Pneumatic or hydraulic cylinders have long been used to power or operate numerous types of machinery, including valve actuators. Thrust is generated by virtue of pressure applied against a piston. One means to increase such thrust is to increase the piston size. Such increase in piston size is limited by such parameters as the capabilities of the machine tools and materials used to fabricate the pistons. When the practical limits of such parameters have been reached, multiple cylinders, in tandem arrangement, including a common piston rod, were developed for use. The pressure boundaries of such tandem arrangement of cylinders are the end caps of each cylinder as well as the common wall or end cap dividing adjacent cylinders. Such intermediate cap or wall is generally thin, as a result of design pressure and material strength. As a result, it provided insufficient thickness, on its outer diameter, to install a pressure port adequate for tandem cylinder devices used in many high speed applications. It was to eliminate this increased thickness of the common wall, as well as the accompanying increased length and external piping required, as well as to reduce the size of the external valving and piping, that this invention was directed.
SUMMARY OF THE INVENTION
Linearly arranged, tandem cylinders, are joined by a common end cap or wall. A common piston rod reciprocates through an opening in said common wall, and carries opposed pistons, one for oscillation in each said cylinder. Appropriate piping provides pressurized fluid from a supply source to like positioned faces of each piston. Valve means is provided, preferably within said common wall, permitting fluid exhaust from one cylinder to the other, whereby quick pressure equalization occurs between adjacent areas of the tandem arranged cylinders.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partly schematic vertical section of the tandem cylinder arrangement, and controls therefor, of this invention;
FIG. 2 is an enlarged detail of the tandem cylinders and quick release valve.
DESCRIPTION OF THE INVENTION
A pair of cylinders 10 and 50 are linked end to end via a common end cap or wall 30. Each cylinder is releasably joined, at one of its ends, to said common end cap, by some convenient means (not shown), such as guide rods or other threaded fastener. The other end of each cylinder would be closed by its respective end cap 12 or 32.
Slidably and sealingly received by common end cap 30 and by end cap 12 of cylinder 10, it a common piston rod 20. Secured to and carried by said piston rod are pistons 21, 22 for reciprocation within each piston's respective cylinder cavities "A" and "B". Said pistons carry annular seals 23, for sealing engagement with the inner wall of the two cylinders. Piston 22 is secured to one end of rod 20, while piston 21 is secured to said rod intermediate its ends. Said piston rod also carries spring guide 24 for seating one end 26 of coil spring 25. Said spring is provided for biasing pistons 21 and 22 toward end cap 12 and common end cap 30, respectively, i.e., to the left in the drawings. Vents 33 and 34 are provided to vent cylinders A and B from the space intermediate pistons 21, 22 and the common end cad 30 and end cap 32, respectively. Vent passageway 33-A extends through common end cap 30.
Supply pressure inlets 41, 42 are provided respectively to end cap 12 and common end cap 30, respectively to pressurize cavities "A" and "B", urging pistons 21 and 22 in the direction of common end cap 30 and end cap 32, respectively. Pressure passageway 42A extends through common end cap 30.
Equalizing pressure passageway 61 communicates between cavities "A" and "B". Positioned therein is valve assembly 62, which may be, for example, of the butterfly or ball type. The operation of such valve assembly is governed by control 63, which may be a rack and pinion or spring return type actuator made by Bettis Corporation, which, in turn is activated by supply pressure.
Consider the structure and operation of the external piping of the invention. A source of supply or operating fluid (hydraulic or pneumatic) under pressure is illustrated schematically at 100, while a similar source of pilot control fluid is shown at 110. Such pilot fluid regulates the position of both 3-way valves 120 and 130, and thereby the flow of supply fluid to cylinders 10, 50 as well as to equalizer valve control 63. On pilot control fluid being caused to flow through lines 121, 131, valves 120, 130 are moved to their open position whereby supply fluid would pass through the valves to control 63 and to junction 122 from where the supply fluid would flow into cylinder 10 through inlet 41 as well as into cylinder 50 through inlet 42. The supply fluid would exert force against the left-hand faces of pistons 21 and 22, urging them to the right in FIGS. 1 and 2, against the force of spring 25. The reciprocating, linear motion of piston rod 20 would likely be used to translate linear motion into rotary motion. For example, a transverse pin (not shown) may be carried by rod 20, or an extension thereof. Such pin may ride in the slots possessed by the spaced arms of a scotch yoke valve actuator, such as those manufactured by Bettis Corporation.
Equalizer valve control 63, through control apparatus such as actuator arm 132, on receiving supply fluid, would close equalizer valve 62, preferably by causing counter clockwise rotation of actuator arm 132. In the absence of supply pressure, said equalizer valve would remain open, thereby equalizing pressure on opposite sides of common end cap or wall 30.
After movement of pistons 21 and 22 in the direction of the arrows to their right-hand position, on a signal reaching pilot control 110, pilot fluid ceases to be provided to valves 120, 130, shifting their spools to the exhaust position. Such shifting of valve 130 results in equalizer valve control 63 opening equalizer valve 62. On this occurring, almost immediately, pressure on opposite sides of wall or cap 30 is equalized. This allows pressure to be vented through a smaller size vent 33 than would otherwise be possible. Spring 25 would return the piston rod 20, to its left-hand position. On pilot pressure again being available, the next cycle would begin.
Although only a single embodiment has been described, it should be obvious that numerous modifications would be possible by one skilled in the art without departing from the spirit of the inventions the scope of which is limited only by the following claims.
|
Tandem arranged cylinders having a common wall therebetween, with a common piston rod extending through said common wall, said rod carrying a piston for reciprocation within each said cylinder, and a valve member for fluid communication between said cylinders, permitting pressure equalization therebetween.
| 5
|
This is a division of application Ser. No. 08/831,932 filed on Apr. 2, 1997 of Perry A. Ratcliff for "METHOD FOR TREATING ABNORMAL CONDITIONS OF THE EPITHELIUM OF BODILY ORIFICES", now U.S. Pat. No. 5,834,003 which is a continuation application of Ser. No. 08/444,550 filed May 19, 1995 entitled "METHOD FOR TREATMENT OF ABNORMAL CONDITIONS OF THE EPITHELIUM OF BODILY ORIFICES", now U.S. Pat. No. 5,618,550, which is a divisional application of Ser. No. 08/087,606, filed Jul. 6, 1993 entitled "COMPOSITION FOR TREATMENT OF ABNORMAL CONDITIONS OF THE EPITHELIUM OF BODILY ORIFICES", now U.S. Pat. No. 5,489,435.
BACKGROUND OF THE INVENTION
The present invention is directed to a method and composition for prevention and treatment of abnormal conditions of the epithelium of bodily orifices. More particularly, the present invention relates to the use of activated stabilized chlorine dioxide in conjunction with a phosphate compound (to provide stability and as a surfactant or nonsudsing detergent to reduce surface tension on mucosal tissues assisting in the exposure of the epithelial covering to the activated chlorine dioxide), to thereby prevent and treat fungal and bacterial infections of the rectal, vaginal, urethral, oral, nasal, ocular, and auditory canal orifices, and other abnormal conditions of the epithelium, including leukoplakia.
Thiols, particularly the volatile sulfur compounds such as hydrogen sulfide, methylmercaptan and dimethylsulfide, are recognized in the current literature as being major contributors to the penetration of bacterial toxins through the epithelial barrier into the underlying lamina and connective tissue. A. Rizzo, Peridontics, 5:233-236 (1967); W. Ng and J. Tonzetich, J. Dental Research, 63(7):994-997 (1984); M. C. Solis-Gaffar, T. J. Fischer and A. Gaffar, J. Soc. Cosmetic Chem., 30:241-247 (1979); I. Kleinberg and G. Westbay, J. Peridontol, 63(9): 768-774 (1992). The penetration of this barrier makes possible the invasion of antigenic substances such as viral and bacterial toxins and bacteria into the underlying substrate. Thus, by removing the volatile sulfur compounds and maintaining the epithelial barrier there is a reduction in the penetration capacity of antigens and microbiota (A. Rizzo, Peridontics, 5:233-236 (1967); W. Ng and J. Tonzetich, J. Dental Research, 63(7): 994-997 (1984); M. C. Solis-Gaffar, T. J. Fischer and A. Gaffar, J. Soc. Cosmetic Chem., 30:241-247 (1979)) as well as the destruction of the motility and the death of bacterial and viral forms.
Studies done in the mouth have demonstrated that the penetration of bacteria takes place in the presence of the volatile sulfur compounds, resulting in initiation of the inflammatory reaction including initiation of the complement cascade. I. Kleinberg and G. Westbay, J. Peridontol, 63(9): 768-774 (1992). Initiation of the inflammatory reaction and development of the complement leads to an eightfold increase in the cell division or mitosis of epithelial cells in the attachment apparatus of the gingiva. W. O. Engler, S. P. Ramfjiord and J. J. Hiniker, J. Periodont., 36:44-56 (1965). Because the epithelia of other orifices, and particularly vaginal epithelium, are very similar to the gingival epithelium, reactions similar to those described above for the gingival epithelium occur in all other parts of the body, as demonstrated by the occurence of vaginitis and endometriosis of the vagina. Examples of such bacteria which may appear in any bodily orifice include Porphyromonas (formerly known as Bacteroides) gingivalis, Actinobacillus actinomycetemcomitans, and Pseudomonades.
The volatile sulfur compounds are generated primarily from the polypeptide chains of the epithelial cell walls, and from the cell walls, pili, fimbrae, and flagella of microorganisms, including fungi, that are part of the normal flora of the organs of the exposed surfaces of the body. The polypeptide chains are composed of a series of amino acids including cysteine, cystine, and methionine, each of which contain sulfur side chains. The death of the microorganisms or the epithelial cells results in degradation of the polypeptide chains into their amino acid components, particularly cysteine and methionine, which then become the source of the sulfur compounds hydrogen sulfide, methylmercaptan and di-methylsulfide which alter the epithelial barrier, permitting penetration of the barrier by antigenic substances.
Penetration of the epithelial barrier by volatile sulfur compounds reduces the capacity of the tissues to protect against bacteria, virus, fungus, and yeast forms. Tonzetich has shown, using S 35 -labelled methylmercaptan, the penetration of thiol through the epithelium, plus the basal lamina, into the underlying connective tissues where it begins degradation of collagen fibers. W. Ng and J. Tonzetich, J. Dental Research, 63(7): 994-997 (1984). In addition, it is the nature of many of the bodily orifices that they are inhabited by both pathogenic and non-pathogenic organisms. If an antibiotic is used to reduce the organisms normally present, opportunistic yeast forms and other pathogenic organisms resistant to the administered antibiotic often invade or multiply at or in the bodily orifices.
Candida species, particularly Candida albicans, are the yeasts that primarily affect the mouth and the female vagina. In the mouth, infection by Candida is called Thrush; in the vagina it is called vaginitis.
With the increase of patients having immunocompromising diseases such as AIDS, leukemia, diabetes and immunosuppressing diseases such as stress, alcoholism, etc., a progressively higher percentage of the human population is susceptible to invasion and growth of bacterial and fungal Candida organisms. In addition, such patients are susceptible to the development of conditions of leukoplakia such as oral hairy leukoplakia and leukoplakia vulvae.
In patients afflicted with diabetes, as well as familial history diabetes, the neutrophil, which is the first line defense cell against foreign antigens, has an altered 110 Dalton surface protein which reduces the capacity of the neutrophil to phagocytize bacteria by approximately 50%. R. J. Genco, T. E. Van Dyke, M. J. Levine, R. D. Nelson and M. E. Wilson, J. Dental Research, 65(12):1379-1391 (1986). As a result of the development of antibiotics, insulin, and more sophisticated methods of treating diabetes, early deaths of diabetics from infections have been prevented, resulting in a several-fold increase in the number of familial history diabetes in the population. Thus, the increased presence of the diabetes gene in the gene pool of the human race is rapidly increasing, resulting in a higher number of humans with an immunocompromised capacity. This fact in part explains why some women develop vaginitis whenever they are treated with antibiotic drugs.
3. Stability of Chlorine Dioxide
Chlorine dioxide is unstable in aqueous solutions at lower pH levels. It is produced commercially and shipped in an aqueous solution in its hydrolytic byproduct forms at 8.3 to 9.0 pH. At that range there is complete retention of the chlorine dioxide hydrolyzed forms within the solution so that a shelf life of from 1-5 years may be achieved. When the pH of chlorine dioxide is lowered to 7.2 or below, chlorine dioxide begins to become activated and, in the gaseous form, it is available for reactivity with thiols, microorganisms, and organic debris in solution.
At present, there is an inadequate capacity of existing pharmaceutical drugs to control Candida infections (IADR symposium, March 1993). The severe diseases may be resistant to the commonly used drugs ketonideozole and nystatin, etc. Other synthetic drugs which are used systemically may have limited effects, and infections are resistant to treatment. Combinations of these drugs systemically and by suppositories may not always work.
In an in vitro study by the present inventor of Candida culture using the protocol of a simulated oral environment as stipulated by the Food and Drug Administration in the Federal Register, Vol. 47, No. 101 (May 25, 1982), wherein calf serum is added to the tryptic soy broth inoculated with the Candida, one ml. of the Candida culture was withdrawn and plate counted by standard techniques to determine the baseline content of the Candida population. Both a solution and a slurry of 1 ml. paste containing 0.1% chlorine dioxide with 0.2% phosphate stabilizer plus 2 ml. of distilled water was added to the TSB broth with calf serum. Additional samples were taken at 10, 30 and 60 seconds and again plated to count the remaining Candida. It was found that at 10 seconds there was a 99+% reduction of Candida albicans using standard plate count techniques.
In a six month clinical trial by the present inventor, samples were taken from the gingival crevice of the mouth. After treatment of humans with a composition comprising 0.10% chlorine dioxide and 0.2% phosphate stabilizer, the inventor showed by means of standard plate count methods that during the period from baseline to six months, there was a statistically significant reduction of Candida albicans. This clinical trial demonstrates the capacity of a composition comprising 0.1% activated stabilized chlorine dioxide together with metallic phosphate (the latter compound acting both to stabilize the chlorine dioxide solution and also as a surfactant to break the surface tension and allow chlorine dioxide to effectively interact with the Candida albicans infection) to prevent and treat the development of a Candida infection.
Further details of the preparation and use of chlorine dioxide/phosphate compositions can be found in U.S. Pat. No. 5,200,171, issued Apr. 6, 1993 to Ratcliff, which is hereby incorporated by reference.
SUMMARY OF THE INVENTION
Briefly, and in accord with one embodiment of the present invention, a composition containing stabilized chlorine dioxide and a phosphate is disclosed as being useful in preventing and treating abnormal conditions of the epithelium of bodily orifices. Examples of such abnormal conditions of the epithelium of the rectal, vaginal, urethral, oral, nasal, ocular, and auditory canal orifices include bacterial and fungal infections, such as Candida, and leukoplakia. Stabilized chlorine dioxide is an effective agent for removing thiol compounds for deodorizing the mouth as well as deodorizing other bodily orifices, such as the vagina. The addition of activating inhibitor phosphates to the stabilized chlorine dioxide reduces surface tension and retards the rapid escape of chlorine dioxide gas at the pH range of 6.5 to 7.0 typical of orifices of the body. Preferred concentrations of stabilized chlorine dioxide compounds are in the range of between about 0.005% to 2.0%. The concentration of the phosphate compound, preferably disodium hydrogen phosphate, sodium dihydrogen phosphate, trisodium phosphate, and sodium monofluorophosphate, is in the range of between about 0.02 to 3.0%.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Broadly, the present invention contemplates the use of an activating inhibitor and surface tension reducing agent, specifically, a phosphate compound, preferably, disodium hydrogen phosphate, sodium dihydrogen phosphate, trisodium phosphate, or sodium monofluorophosphate (in particular, trisodium phosphate, or sodium monofluorophosphate), combined with a stabilized chlorine dioxide solution, to make possible the lowering of the pH of the mixture to an optimal value of less than about 7.2 at the time the mixture is used to prevent and treat abnormal conditions of the epithelium of bodily orifices, such as those caused by fungal and bacterial infections of the rectal, vaginal, urethral, oral, nasal, ocular, and auditory canal orifices, and other abnormal conditions of the epithelium, including leukoplakia.
The present invention can be used to control the above-described bodily orifice maladies in humans, and animals which are human companions, such as dogs, cats, horses, etc., by reducing the presence of fungal and bacterial infections and leukoplakia in bodily orifices of the human and animal population, to prevent transference and cross infection from person to person or animal to person or animal to animal. Thus, the present invention can be used in both human and veterinary applications.
Clinical observations and in vitro and in vivo studies by the inventor have led to the discovery that an activating inhibitor phosphate such as disodium monohydrogen phosphate, sodium dihydrogen phosphate, or, preferably, trisodium phosphate, or sodium monofluorophosphate, causes a reduction in surface tension, as well as stabilizing chlorine dioxide, so that the chlorine dioxide remains effective at a lower pH than was previously thought possible. In addition, the phosphate is a detergent which is used in place of other detergents for lowering surface tension and allowing the activated chlorine dioxide to become available to the convoluted surfaces of the body orifices. The preferred concentration ranges are between about 0.005%-2.0% chlorine dioxide, and between about 0.02%-3.0% phosphate. For most patients, the preferred concentration of chlorine dioxide will be in the range of between about 0.005-0.5%; in the case of extremely immunocompromised patients having runaway bacterial or fungal infections or severe leukoplakia, it is preferred to increase the concentration of chlorine dioxide up to about 1.0-2.0%.
The permeability of mucus epithelial tissue is increased substantially by exposure to thiol compounds including hydrogen sulfide (H 2 S) and methylmercaptan (CH 3 --SH) and dimethylsulfide (CH 3 --S--CH 3 ). In a Candida infection, there is increased inflammation and degeneration of epithelial cells, which break down into thiols, including the above sulfur compounds. A vicious cycle is established, leading to an environment for the increase of Candida growth. If the patient is immunocompromised with AIDS, the problem is exacerbated with ulcerations that could increase the probability of sexually transmitted disease. Likewise, a non-AIDS patient could be more exposed to sexually transmitted disease.
The following examples further illustrate various features of the invention but are intended in no way to limit the scope of the invention which is defined in the appended claims.
EXAMPLE 1
The Stability of Chlorine Dioxide at Ph 6.8 in the Presence of Phosphate
Materials:
1. Purogene (2% ClO 2 ), Lot #8907.41, 1 gallon, Manufactured by BIO-Cide, International, P.O. Box 2700, Norman, Okla. 73070.
2. Sodium Phosphate, monobasic, dibasic, and tribasic.
Methods:
A 10% solution of monobasic sodium phosphate was prepared in distilled water. Ten ml was placed into each of four beakers. One of each of the four beakers received 1, 2.5, 5, and 10 ml of chlorine dioxide concentrate (2% ClO 2 ), respectively. All solutions were diluted to 90 ml with distilled water, adjusted to pH 6.8 with 1N NaOH and 1N HCl, diluted to 100 ml and placed in screw cap bottles.
Solutions containing dibasic and tribasic sodium phosphate and a distilled water blank control were prepared in a similar manner.
Chlorine dioxide content and pH was determined for each solution on days 0, 7, 14, 21 and 28 in accordance with Standard Methods for the Examination of Water and Wastewater, 17th edition, 1989.
Results and Summary:
As shown in Table 1, the content of chlorine dioxide was stable in all sodium phosphate solutions and distilled water control over the 28 day test period. The pH of all samples ranged from 6.1 to 7.6.
TABLE I__________________________________________________________________________RESULTS SHOWING THE STABILITY OF CHLORINE DIOXIDE SOLUTION AT pH 6.8IN DISTILLED WATER AND 1% SODIUM PHOSPHAGE, MONOBASIC, DIBASIC, ANDTRIBASIC DAY Theroetical 0 7 14 21 28SOLUTION % ClO.sub.2 pH % ClO.sub.2 pH % ClO.sub.2 pH % ClO.sub.2 pH % ClO.sub.2 pH % ClO.sub.2__________________________________________________________________________Distilled Water 0.02 6.8 0.02 6.9 0.02 6.9 0.02 6.5 0.02 6.5 0.02 0.05 6.8 0.05 6.9 0.05 6.9 0.05 7.1 0.05 6.9 0.05 0.1 6.8 0.1 6.9 0.1 7.0 0.1 7.7 0.1 7.6 0.1 0.2 6.8 0.2 6.9 0.2 6.9 0.2 7.2 0.2 7.2 0.20/0 Na.sub.2 HPO.sub.11 0.02 6.8 0.02 6.1 0.02 6.7 0.02 6.7 0.02 6.8 0.02(Disodium 0.05 6.8 0.05 6.8 0.05 6.8 0.05 6.8 0.05 6.8 0.05hydrogen 0.1 6.8 0.1 6.9 0.1 6.9 0.1 6.8 0.1 6.8 0.1phosphate) 0.2 6.8 0.2 6.9 0.2 6.9 0.2 6.9 0.2 6.8 0.20/0 NaH.sub.2 PO.sub.4 0.02 6.8 0.02 6.7 0.02 6.8 0.02 6.7 0.02 6.8 0.02(Sodium 0.05 6.8 0.05 6.8 0.05 6.8 0.05 6.8 0.05 6.9 0.05dihydrogen 0.1 6.8 0.1 6.8 0.1 6.8 0.1 6.9 0.1 6.9 0.1phosphate) 0.2 6.8 0.2 6.8 0.2 6.8 0.2 6.9 0.2 6.9 0.20/0 Na.sub.3 PO.sub.4 0.02 6.8 0.02 6.8 0.02 6.4 0.02 6.9 0.02 7.0 0.02(Trisodium 0.05 6.8 0.05 7.0 0.05 7.1 0.05 6.9 0.05 7.0 0.05phosphate) 0.1 6.8 0.1 7.5 0.1 7.5 0.1 7.0 0.1 6.9 0.1 0.2 6.8 0.2 7.0 0.2 7.1 0.2 6.9 0.2 6.9 0.2__________________________________________________________________________
EXAMPLE 2
The Stability of Chlorine Dioxide at Ph 6.8 in the Presence of 0.2% Phosphate
The following is an example of how to test the stability of chlorine dioxide at pH 6.8 in the presence of 0.2% phosphate.
Materials:
1. Purogene (2% ClO 2 ), Lot #8907.41, 1 gallon, Manufactured by BIO-Cide, International, P.O. Box 2700, Norman, Okla. 73070.
2. Sodium Phosphate, monobasic, dibasic, and tribasic.
Methods:
A 0.2% solution of monobasic sodium phosphate is prepared in distilled water. Ten ml is placed into each of four beakers. One of each of the four beakers receives 1, 2.5, 5, and 10 ml of chlorine dioxide concentrate (2% ClO 2 ), respectively. All solutions were diluted to 90 ml with distilled water, adjusted to pH 6.8 with 1N NaOH and 1N HCl, diluted to 100 ml and placed in screw cap bottles.
Solutions containing dibasic and tribasic sodium phosphate and a distilled water blank control are prepared in a similar manner.
Chlorine dioxide content and pH is determined for each solution on days 0, 7, 14, 21 and 28 in accordance with Standard Methods for the Examination of Water and Wastewater, 17th edition, 1989, in order to determine the stability of chlorine dioxide over time.
EXAMPLE 3
The Effectiveness of Chlorine Dioxide in Phosphate Mixture Against Candida albicans
Materials:
1. Purogene (2% chlorine dioxide), lot #8907:41, manufactured by BIO-CIDE International, Inc., P.O. Box 2700, Norman, Okla. 73070.
2. Test Organism: Candida albicans (ATCC #18804)
3. Saline, 0.9% NaCl.
4. Butterfield's Buffer phosphate dilutent (BFB), pH 7.2.
5. Sterile 15% sodium thiosulfate.
6. Blood agar.
7. Stop watch.
8. Sterile 1N HCl and 1N NaOH.
9. pH meter.
10. McFarland nephelometer tube No. 1. Density of this tube is equivalent to a bacterial suspension of 3×10 8 organisms per ml.
11. N,N-diethyl-p-phenylenediamine (DPD reagent).
12. Phosphate buffer reagent.
13. Sodium dihydrogen phosphate, NaH 2 PO 4 .7H 2 O.
14. Trisodium phosphate, Na 3 PO 4 .12H 2 O.
15. Sodium monofluorophosphate, Na 2 FPO 3 , Ref No. OB 12837, manufactured by Albright and Wilson, P.O. Box 80, Oldbury, Narley, West Midlands, B694LN, England.
DPD reagent and phosphate buffer reagent were prepared in accord with Standard Methods for the Examination of Water and Wastewater, 17th Edition, p. 9-54 (1989).
Methods:
1. Test Solutions:
A ten percent sodium dihydrogen phosphate solution was prepared in distilled water. Ten ml was placed into each of five beakers. One of each of the five beakers received 0, 1, 2.5, 5, and 10 ml of chlorine dioxide concentrate (2% ClO 2 ), respectively. All solutions were diluted to 90 ml with distilled water, adjusted to pH 6.0 with 1N NaOH and 1N HCl, diluted to 100 ml and placed in screw cap bottles. Solutions containing 0 ppm chlorine dioxide were filter sterilized prior to use.
Solutions containing trisodium phosphate and sodium monofluorophosphate were prepared in a similar manner.
II. Test Suspensions:
Suspensions of the Candida albicans organism were prepared in Butterfield's buffer from 48 hour agar cultures and turbidity adjusted to a McFarland Tube #1. Subsequently 0.1 ml of this suspension was diluted in 50 ml of saline. The diluted microorganism suspensions were now ready for use.
III. Test Procedure:
1. Test:
One ml of test suspension was aliquoted into each of five sterile 16×125 mm screw cap tubes. Each of the five tubes received 4 ml of a solution containing either 0, 200, 500, 1000, or 2000 ppm chlorine dioxide in 1% sodium dihydrogen phosphate. Each tube was shaken for ten seconds and immediately inactivated with 0.25 ml 15% sodium thiosulfate. Solutions containing 1% trisodium phosphate and 1% sodium monofluorophosphate were handled in a similar manner.
2. Controls:
One ml of test suspension was dispensed into two sterile 16×125 mm screw cap tubes. Each tube received 4 ml 2000 ppm chlorine dioxide in 1% sodium dihydrogen phosphate. The first tube received 0.25 ml sodium thiosulfate, while the second tube received none. Subsequently each tube was tested for residual chlorine dioxide by adding 0.3 ml phosphate buffer reagent and 0.3 ml DPD reagent to each tube. Neutralized tubes were colorless, while nonneutralized tubes were pink. Solutions of trisodium phosphate and sodium monofluorophosphate containing 2,000 ppm chlorine dioxide were handled in a similar manner.
One ml test suspension of the Candida albacans organism was treated with 4 ml Butterfield's buffer and 0.25 ml 10% sodium thiosulfate as a negative control.
After inactivation with sodium thiosulfate all tubes were plate counted.
Sterility tests on all reagents were run parallel to experiments by plate counted method. The plate counted method and sterility tests were conducted in accord with Standard Methods for the Examination of Water and Wastewater, 17th Edition, p. 9-54 (1989).
Results and Summary:
As shown in Table 2, 99-100% of the Candida albicans organisms were killed when challenged with 1,000 ppm (0.1%)-2,000 ppm (0.2%) chlorine dioxide in either 1% sodium dihydrogen phosphate or trisodium phosphate. Chlorine dioxide concentrations of 200 (0.02%) and 500 ppm (0.05%) in the presence of phosphates demonstrated marginal bacteriocidal activity against C.albicans (39-51% kill).
TABLE 2______________________________________RESULTS SHOWING THE BACTERIOCIDAL ACTIVITY OFCHLORINE DIOXIDE IN PHOSPHATE SOLUTIONS ATpH 6.0 AGAINST CANDIDA ALBICANSPHOSPHATE SOLUTIONCLO.sub.2 Negative(PPM) Control* 1% NaH.sub.2 HPO.sub.4 1% Na.sub.2 PO.sub.4______________________________________0 95,000** 64,000 (33)*** 55,000 (42)200 ND 58,000 (39) 64,000 (33)500 ND 47,000 (51) 32,000 (60)1000 ND 250 (99) 0 (100)2000 ND 17 (90) 5 (99)______________________________________ *Butterfield's buffer **Organisms/ml ***Percent Kill ND = Not Done
EXAMPLE 4
The Effectiveness of Chlorine Dioxide in Phosphate Mixture Against Candida albicans in the Presence and Absence of Serum
Materials:
1. Purogene, Lot #8907:41, 1 gallon (contains 2% ClO 2 ), manufactured by BIO-CIDE International, Inc., P.O. Box 2700, Norman, Okla. 73070.
2. Test Organism: Candida albicans (ATCC #18804) obtained from American Type Culture Collection, (ATCC) 12301 Parklawn Drive, Rockville, Md. 20852.
3. 15% Sodium thiosulfate (Na 2 S 2 O 3 )
4. Plate Count agar
5. Newborn calf serum, Colostrum free, Lot #30P7485, Gibco Laboratories, Grand Island, N.Y., 14072.
6. Butterfield's Buffer, pH 7.2
7. Trisodium phosphate, Na 3 PO 4 .12H 2 O, Sigma Chemical Co., St. Louis Mo. 63178.
Methods:
Chlorine dioxide solution having concentrations of 0, 200, 500, 1,000 and 2,000 mg/L were prepared from Purogene concentrate. Each ClO 2 concentration was prepared to contain 0.5% tribasic sodium phosphate (i.e., trisodium phosphate, Na 3 PO 4 .12H 2 O). In a similar manner, chlorine dioxide solutions of 0, 200, 500, 1,000 and 2,000 mg/L were prepared, with each solution containing 1.0% tribasic sodium phosphate. The pH of the chlorine dioxide/phosphate mixture was adjusted to 6.5 with 1N and 6N hydrochloric acid.
Tryptic Soy Broth (100 ml) was innoculated with Candida albicans and incubated 24 hours at 35° C. After incubation, the cells were washed three times with Butterfield's buffer and resuspended in 100 ml buffer.
Testing in the absence of Serum:
Chlorine dioxide-phosphate solutions (100 ml) were dispensed into sterile 16×125 mm screw cap tubes, 9 ml/tube. Three tubes were prepared for each ClO 2 concentration. One ml of washed C.albicans suspension was added to one tube of each ClO 2 concentration, and mixed vigorously for 10 seconds. One minute after addition of ClO 2 , 2 ml of 15% sodium thiosulfate (Na 2 S 2 O 3 ) was added to each tube and well mixed to inactivate the mixture. The procedure was repeated twice with the remaining tubes except that ClO 2 was inactivated with sodium thiosulfate after 2 and 5 minutes respectively.
Serial ten-fold dilutions (10 -1 -10 -5 ) of Candida albicans/ClO 2 mixtures were prepared in Butterfield's buffer. Simultaneously, one ml of each dilution was transferred to a sterile 15 mm petri dish. Then 10 ml of plate count agar at 45-47° C. was added to each plate, and the plates were swirled and allowed to solidify. Plates were inverted and incubated 76 hours at 35° C., and colonies counted.
Testing in Presence of Serum:
Chlorine dioxide-phosphate solutions, were aliquoted, 8 ml/tube. Three tubes were prepared per ClO 2 concentration. Fifty ml washed C.albicans suspension was added with 50 ml newborn calf serum. 2 ml of the serum-C.albicans suspension was added to test tubes and processed as described above.
Results:
Results showing percent kill of Candida albicans as a result of application of chlorine dioxide-phosphate solutions are shown in Tables 3 and 4.
TABLE 3______________________________________Results Showing Bacteriocidal Activity of Chlorine Dioxide-Phosphate (0.5%) Solutions at pH 6.5 Against Candida AlbicansTIME ClO.sub.2 w/out Serum (ppm) ClO.sub.2 w/ Serum (ppm)(Seconds) 200 500 1000 2000 200 500 1000 2000______________________________________1 33* 44 99+ 99+ <10 27 18 362 13 33 99+ 99+ 40 30 30 305 29 35 99+ 99+ 13 <10 <10 ND______________________________________ *Percent kill ND = Not done + = greater than
TABLE 4______________________________________Results Showing Bacteriocidal Activity of Chlorine Dioxide-Phosphate (1%) Solutions at pH 6.5 Against Candida AlbicansTIME ClO.sub.2 w/out Serum (ppm) ClO.sub.2 w/ Serum (ppm)(Seconds) 200 500 1000 2000 200 500 1000 2000______________________________________1 30* 65 99+ 99+ <10 <10 <10 <102 37 47 99+ 99+ 19 <10 29 195 17 ND 99+ 99+ <10 <10 <10 <10______________________________________ *Percent kill ND = Not done + = greater than
EXAMPLE 5
The Effectiveness of Chlorine Dioxide in Phosphate Mixture Against Actinobacillus actinomycetemcomitans in the Presence and Absence of Serum
Materials:
1. Purogene, Lot #8907:41, 1 gallon (contains 2% ClO 2 ), manufactured by BIO-CIDE International, Inc., P.O. Box 2700, Norman, Okla. 73070.
2. Actinobacillus actinomycetemcomitans, ATCC #29522, obtained from American Type Culture Collection, 12301, Parklawn Drive, Rockville, Md. 20852.
3. 15% Sodium thiosulfate (Na 2 S 2 O 3 )
4. Plate Count agar
5. Newborn calf serum, Colostrum free, Lot #30P7485, Gibco Laboratories, Grand Island, N.Y., 14072.
6. Butterfield's Buffer, pH 7.2
7. Trisodium phosphate, Na 3 PO 4 .12H 2 O, Sigma Chemical Co., St. Louis Mo. 63178
Methods:
Chlorine dioxide solutions having concentrations of 1,000 and 2,000 mg/L were prepared from Purogene concentrate. Each ClO 2 concentration was prepared to contain 0.2% sodium phosphate, tribasic (i.e., trisodium phosphate, Na 3 PO 4 .12H 2 O). The pH of the chlorine dioxide/phosphate mixture was adjusted to 6.5 with 1N hydrochloric acid.
Three chocolate agar plates were inoculated with Actinobacillus actinomycetemcomitans and incubated 48 hours at 35° C. in a candle jar. After incubation, cells were scraped from the plates with a cotton swab and suspended in 100 ml buffer. 50 ml of this suspension was diluted with 50 ml buffer, while the other 50 ml was diluted with 50 ml serum.
Testing in the absence of Serum:
Chlorine dioxide-phosphate solutions (100 ml) were dispensed into sterile 150 ml beakers containing magnetic stir bars. While stirring on a magnetic mixer, a 10 ml portion of A. actinomycetemcomitans-buffer suspension was added. At 10, 30 and 60 second intervals, 10 ml was removed from the beaker and transfered to a 16×125 mm tube which contained 2 ml 15% sodium thiosulfate. The tube was capped, mixed, and a plate count was performed employing chocolate agar as the growth media, in accord with the methods described in FDA Bacteriological Analytical Manual, 6th edition, 1984, chapters 4, 17, herein incorporated by reference.
Testing in Presence of Serum:
Testing in the presence of serum was handled in a similar manner, except that an Actinobacillus actinomycetemcomitans-serum suspension was subtituted for the Actinobacillus actinomycetemcomitans-buffer suspension.
Results:
Results showing percent kill of Actinobacillus actinomycetemcomitans following application of the chlorine dioxide-phosphate solutions are shown in Table 5.
TABLE 5______________________________________Results Showing Bacteriocidal Activity of Chlorine Dioxide-Phosphate (0.2%) at pH 6.5 Against ActinobacillusActinomycetemcomitansTIME ClO.sub.2 w/out Serum (ppm) ClO.sub.2 w/ Serum (ppm)(Seconds) 1000 2000 1000 2000______________________________________10 99* 99+ 99+ 99+30 99+ 99+ 99+ 99+60 99+ 99+ 99+ 99+______________________________________ *Percent kill + = greater than
EXAMPLE 6
The Effectiveness of Chlorine Dioxide in Phosphate Mixture Against Porphyromonas gingivalis in the Presence and Absence of Serum
Materials:
1. Purogene, Lot #8907:41, 1 gallon (contains 2% ClO 2 ), manufactured by BIO-CIDE International, Inc., P.O. Box 2700, Norman, Okla. 73070.
2. Porphyromonas (formerly known as Bacteroides) gingivalis, ATCC #33277, obtained from American Type Culture Collection, 12301 Parklawn Drive, Rockville, Md. 20852.
3. 15% Sodium thiosulfate (Na 2 S 2 O 3 )
4. Plate Count agar
5. Newborn calf serum, Colostrum free, lot #30P7485, Gibco Laboratories, Grand Island, N.Y., 14072.
6. Butterfield's Buffer, pH 7.2
7. Trisodium phosphate, Na 3 PO 4 .12H 2 O, Sigma Chemical Co., St. Louis Mo. 63178.
Methods:
Chlorine dioxide solutions having concentrations of 1,000 and 2,000 mg/L were prepared from Purogene concentrate. Each ClO 2 concentration was prepared to contain 0.2% sodium phosphate, tribasic (i.e., trisodium phosphate, Na 3 PO 4 .12H 2 O). The pH of the chlorine dioxide/phosphate mixture was adjusted to 6.5 with 1N hydrochloric acid. Three anaerobic BAP plates were inoculated with gingivalis (ATCC 33277) and incubated 72 hours at 35° C. After incubation, cells were scraped from the plates with a cotton swab and suspended in 100 ml buffer. 50 ml of this suspension was diluted with 50 ml buffer, while the other 50 ml was diluted with 50 ml serum.
Testing in the Absence of Serum:
Chlorine dioxide-phosphate solutions (100 ml) were dispensed into sterile 150 ml beakers containing magnetic stir bars. While stirring on a magnetic mixer, a 10 ml portion of P.gingivalis-buffer suspension was added. At 10, 30 and 60 second intervals, 10 ml was removed from the beaker and transferred to a 16×125 mm tube which contained 2 ml 15% sodium thiosulfate. Tube was capped, mixed, and an anaerobic plate count was performed using anaerobic blood agar in accord with the methods described in FDA Bacteriological Analytical Manual, 6th edition, 1984, chapter 17.
Testing in Presence of Serum:
Testing in the presence of serum was handled in a similar manner to that described immediately above, except that a Porphyromonas gingivalis-serum suspension was substituted for the Porphyromonas gingivalis-buffer suspension.
Results:
Results showing percent kill of Porphyromonas gingivalis by application of chlorine dioxide-phosphate solutions are shown in Table 6.
TABLE 6______________________________________Results Showing Bacteriocidal Activity of Chlorine Dioxide-Phosphate (0.2%) at pH 6.5 Against PorphyromonasGingivalisTIME ClO.sub.2 w/out Serum (ppm) ClO.sub.2 w/ Serum (ppm)(Seconds) 1000 2000 1000 2000______________________________________10 89* 99+ 82 8630 99+ 99+ 84 9760 99+ 99+ 94 99______________________________________ *Percent kill + = greater than
EXAMPLE 7
A boy diagnosed as having Thrush was treated with the drug ketonideozole for two weeks. The Candida were not controlled. The boy was then treated with a mouthrinse solution and toothpaste both of which contained as the effective ingredient a composition comprising 0.1% chlorine dioxide together with 0.2% trisodium phosphate. The boy's Thrush infection was brought under control within 3 days. The treating pediatrician was surprised and did not understand how the boy's recovery could happen so quickly.
EXAMPLE 8
The present inventor has treated hairy leukoplakia present on the tongue of AIDS-infected patients. The daily use of a toothpaste and mouthrinse, both of which contained as the effective ingredient a composition comprising 0.1% chlorine dioxide together with 0.2% trisodium phosphate, resulted in the disappearance of the hairy leukoplakia within 14 days. When the chlorine dioxide/phosphate-containing products were withdrawn, the hairy leukoplakia returned within 14 days. When the same products were again administered, the hairy leukoplakia again disappeared.
EXAMPLE 9
Hypothetically, the following composition may be prepared:
Stabilized chlorine dioxide at least 0.1%
Phosphate compound at least 0.05%
Preferable phosphate compounds include disodium hydrogen phosphate, sodium dihydrogen phosphate, trisodium phosphate, or sodium monofluorophosphate, in particular trisodium phosphate or sodium monofluorophosphate.
The above composition may be applied on a daily basis to the vagina of a patient afflicted with vaginitis. It is predicted that the patient will experience a cessation of vaginitis symptoms as a result of the regular administration of the composition.
EXAMPLE 10
Hypothetically, the following composition may be prepared:
Stabilized chlorine dioxide at least 0.1%
Phosphate compound at least 0.05%
Preferable phosphate compounds include disodium hydrogen phosphate, sodium dihydrogen phosphate, trisodium phosphate, or sodium monofluorophosphate, in particular trisodium phosphate or sodium monofluorophosphate.
The above composition may be applied on a daily basis to the vagina of a patient afflicted with leukoplakia vulvae. It is predicted that the patient will experience a cessation of the leukoplakia vulvae symptoms as a result of the regular administration of the composition.
EXAMPLE 11
Hypothetically, the following composition may be prepared:
Stabilized chlorine dioxide at least 0.1%
Phosphate compound at least 0.05%
Preferable phosphate compounds include disodium hydrogen phosphate, sodium dihydrogen phosphate, trisodium phosphate, or sodium monofluorophosphate, in particular trisodium phosphate or sodium monofluorophosphate.
The above composition may be applied on a daily basis to the urethra of a patient infected in that orifice with Actinobacillus actinomycetemcomitans. It is predicted that the patient will experience a cessation of symptoms of the infection as a result of the regular administration of the composition.
EXAMPLE 12
Hypothetically, the following composition may be prepared:
Stabilized chlorine dioxide at least 0.1%
Phosphate compound at least 0.05%
Preferable phosphate compounds include disodium hydrogen phosphate, sodium dihydrogen phosphate, trisodium phosphate, or sodium monofluorophosphate, in particular trisodium phosphate or sodium monofluorophosphate.
The above composition may be applied on a daily basis to the vagina of a patient infected in that orifice with Porphyromonas gingivalis. It is predicted that the patient will experience a cessation of symptoms of the infection as a result of the regular administration of the composition.
EXAMPLE 13
Hypothetically, the following composition may be prepared:
Stabilized chlorine dioxide at least 0.1%
Phosphate compound at least 0.05%
Preferable phosphate compounds include disodium hydrogen phosphate, sodium dihydrogen phosphate, trisodium phosphate, or sodium monofluorophosphate, in particular trisodium phosphate or sodium monofluorophosphate.
The above composition may be applied on a daily basis to the rectum of a patient infected in that orifice with Porphyromonas gingivalis. It is predicted that the patient will experience a cessation of symptoms of the infection as a result of the regular administration of the composition.
EXAMPLE 14
Hypothetically, the following composition may be prepared:
Stabilized chlorine dioxide at least 0.1%
Phosphate compound at least 0.05%
Preferable phosphate compounds include disodium hydrogen phosphate, sodium dihydrogen phosphate, trisodium phosphate, or sodium monofluorophosphate, in particular trisodium phosphate or sodium monofluorophosphate.
The above composition may be applied on a daily basis to the auditory canal of a patient infected in that orifice with Actinobacillus actinomycetemcomitans. It is predicted that the patient will experience a cessation of symptoms of the infection as a result of the regular administration of the composition.
EXAMPLE 15
Hypothetically, the following composition may be prepared:
Stabilized chlorine dioxide at least 0.1%
Phosphate compound at least 0.05%
Preferable phosphate compounds include disodium hydrogen phosphate, sodium dihydrogen phosphate, trisodium phosphate, or sodium monofluorophosphate, in particular trisodium phosphate or sodium monofluorophosphate.
The above composition may be applied on a daily basis to the nasal canal of a patient infected in that orifice with Porphyromonas gingivalis. It is predicted that the patient will experience a cessation of symptoms of the infection as a result of the regular administration of the composition.
EXAMPLE 16
Hypothetically, the following composition may be prepared:
Stabilized chlorine dioxide at least 0.1%
Phosphate compound at least 0.05%
Preferable phosphate compounds include disodium hydrogen phosphate, sodium dihydrogen phosphate, trisodium phosphate, or sodium monofluorophosphate, in particular trisodium phosphate or sodium monofluorophosphate.
The above composition may be applied on a daily basis to the ocular canal of a patient infected in that orifice with Actinobacillus actinomycetemcomitans. It is predicted that the patient will experience a cessation of symptoms of the infection as a result of the regular administration of the composition.
EXAMPLE 17
Hypothetically, the following composition may be prepared:
Stabilized chlorine dioxide 1.0-2.0%
Phosphate compound at least 0.05%
Preferable phosphate compounds include disodium hydrogen phosphate, sodium dihydrogen phosphate, trisodium phosphate, or sodium monofluorophosphate, in particular trisodium phosphate or sodium monofluorophosphate.
The above composition may be applied on a daily basis to the bodily orifices of a severely immunocompromised patient afflicted with leukoplakia, and with opportunistic bacterial and fungal infections. It is predicted that the patient will experience a cessation of leukoplakia and symptoms of infection as a result of the regular administration of the composition.
EXAMPLE 18
A secretary in the employ of the present inventor developed a vaginitis. She called for an appointment with her gynecologist only to learn that she could not be seen for several days. Because of the extreme itching, and knowing, as a consequence of her employment with the present inventor, that activated chlorine dioxide would kill Candida, she of her own initiation and volition used as a douche a mouthrinse developed by the present inventor, which mouthrinse contains 0.1% activated chlorine dioxide and 0.2% trisodium phosphate. She reported that she was asymptomatic immediately upon application of the above composition, with no itching. She took a wet cloth and applied the above composition locally, in the vicinity of the vagina, for three or four days, with no recurrent symptoms.
In the practice of methods to use the compounds of the present invention, an effective amount of the chlorine dioxide/phosphate composition is administered to the subject in need of, or desiring, such treatment. These compounds or compositions may be administered by any of a variety of routes depending upon the specific end use, including topically, as a lotion, creme or solution, by lavage, suppository, or as a nasal drop or spray.
The most suitable route in any given case will depend upon the use, particular active ingredient, the subject involved, and the judgment of the medical practitioner.
A further aspect of the present invention relates to pharmaceutical compositions containing as active ingredients a compound of the present invention which compositions comprise such compound in admixture with a pharmaceutically acceptable, nontoxic carrier. As mentioned above, such compositions may be prepared for use for topical application, particularly in the form of liquid solutions, suspensions, semi-solids, salves or creams, suppositories, or intranasally particularly in the form of nasal drops or aerosols.
It will be readily apparent to those skilled in the art that a number of modifications and changes can be made without departing from the spirit and scope of the present invention. Therefore, it is not intended that the invention be limited by the illustrative examples but only by the claims which follow.
|
A stable solution, cream, salve, or spray composition containing chlorine dioxide and a phosphate, such as disodium hydrogen phosphate, sodium dihydrogen phosphate, trisodium phosphate, and sodium monofluorophosphate, is disclosed for the prevention and treatment of abnormal conditions of the epithelium of bodily orifices. Examples of such abnormal conditions of the epithelium of the rectal, vaginal, urethral, oral, nasal, ocular, and auditory canal orifices brought about by any of leukoplakia, hairy leukoplakia, vaginitis, endometriosis, Candida Albicans, Actinobacillus actinomycetemcomitans, Porphyromonas gingivalis, Pseudomonades, Candida species, and leukoplakia vulvae. The preferred concentration ranges are between about 0.005%-2.0% chlorine dioxide, and between about 0.02%-3.0% phosphate. The phosphate compound retards escape of chlorine dioxide in the pH range of 6.0 to 7.4, at which pH chlorine dioxide becomes activated and releases sufficient chlorine dioxide to reduce motility and become lethal to the involved micro-organisms.
| 8
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an antenna apparatus provided on a mobile body such as an automobile and a ship for receiving radio waves emitted from a satellite such as a broadcast satellite.
2. Description of the Related Art
In a conventional antenna apparatus for a mobile body, as described in Japanese Patent Unexamined Publication No. 02-159802, a planar antenna is divided into a plurality of antennas and a drive signal in an azimuth direction and an elevation direction of the planar antenna is produced from a phase angle indicative of a delay phase of a received signal of a second antenna with respect to a received signal of a first antenna, and an electric motor is driven through a motor driver on the basis of the drive signal to control an attitude of the antenna and the antenna may automatically track to always face toward the satellite. Further, in order to determine whether the antenna catches the satellite or not, an elevation angle of the antenna is changed at intervals of a predetermined pitch and the antenna is rotated in the horizontal direction at each elevation angle. Thus, when a side lobe peak power of the received signal exceeds a predetermined threshold level S, it is judged that the antenna catches the satellite. Japanese Patent Unexamined Publication Nos. 2-206779 and 2-216074 disclose inventions relating to the present invention.
An automatic gain control (AGC) of a tuner unit of the conventional antenna apparatus is attained by a feedback circuit in order to maintain the received signal at a constant level. When radio waves are cut off, the tuner unit of the antenna apparatus is automatic-gain-controlled to maintain a gain of the tuner unit at the value at which the antenna apparatus has caught the satellite, to thereby make determination of a peak position and detection of a main lobe on the basis of signals received up to that time. Such a conventional method has no problem regarding the peak determination and detection of the main lobe, but since a half-power angle of the main lobe is narrow, it has a problem of a narrow detectable width in scanning made on the basis of a signal obtained by subtracting a threshold level from the received signal. Consequently, it is necessary to make narrow a set interval of elevation angle of the antenna apparatus resulting in many times of scanning, so that a time required to retrack the satellite is increased.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a receiving antenna apparatus for receiving broadcast by satellite including automatic tracking means capable of catching the satellite in a short time after electric waves are cut off.
In order to achieve the above object, the present invention receiving antenna apparatus for receiving broadcast by satellite and which is provided on a mobile body, coarsely detects an incoming direction of radio waves to limit a searching area and reduces a gain of a tuner to such a gain for tracking control that can detect a power peak based on signal level and determine a main lobe, so that a narrow and detailed searching operation is made only within the limited searching area. More particularly, the receiving antenna apparatus of the present invention comprises gain setting means for varying a gain set for AGC of the tuner, whereby the gain is set to a first gain by the gain setting means to perform a coarse search and then reduced to a second gain, lower than the first gain, so as to perform a fine search.
With the above configuration, since the gain of the tuner is increased to a desired value for the search operation on the signal level, a time required to detect a rough incoming direction of radio waves can be made short and the whole time for catching the satellite can be reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a receiving antenna apparatus for receiving broadcast by satellite according to one embodiment of the present invention;
FIG. 2 is a sectional view of the receiving antenna apparatus of the embodiment of FIG. 1;
FIG. 3 is a circuit diagram schematically illustrating a circuit in the receiving antenna apparatus of the embodiment;
FIG. 4A schematically illustrates a data format of an error signal;
FIG. 4B is a graph illustrating a characteristic of the error signal of FIG. 4A;
FIG. 5 is a three-dimensional graph illustrating an output of a tuner;
FIG. 6 is a graph illustrating an example of the output of the tuner;
FIG. 7 is a graph illustrating another example of the output of the tuner;
FIG. 8 is a flow chart showing a method for detecting a power peak when the direction has been detected;
FIG. 9 schematically illustrates a four-step scanning operation;
FIG. 10 schematically illustrates a coarse detection operation; and
FIG. 11 is a diagram showing waveforms of outputs of a main lobe.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 schematically illustrate a structure of an embodiment of an antenna apparatus of the present invention suitable for mounting on a mobile body. FIG. 1 is a plan view of the antenna apparatus in which a radome 2 is removed and FIG. 2 is a partially sectional view of the antenna as viewed from a side thereof.
A housing 1 is covered by the radome 2 and encloses all of circuits and mechanical units of the antenna apparatus. The antenna apparatus is configured as shown in FIG. 2 and is mounted on a roof of the mobile body such as a train, an automobile or a ship. An antenna unit A which is a main portion of the antenna apparatus includes first and second antenna boards 3 and 4 formed as a planar antenna and a connecting plate 5 for connecting the two boards. The boards 3 and 4 and the plate 5 form a substantial Z shape as shown in FIG. 2.
Each of the first and second antenna boards 3 and 4 forms a tilt angle θ or an offset angle from the right angle with the connecting plate 5. The tilt angle θ is set to at least 0° or more, preferably up to 40° in Japan because of the practical drive angle range (23° C. to 53°), so that the first and second antenna boards 3 and 4 may not be overlapped within an incoming path of a received signal even if the antenna unit A is rotated in the elevation direction within the practical drive angle range. In the embodiment, for simplification, the tilt angle θ is set to zero.
Disposed within the first and second antenna boards 3 and 4 are, for example, a first portion of an antenna circuit designated as numeral 16a and a second portion of the antenna circuit designated as 16b in FIG. 3. A drive direction of the antenna unit is determined on the basis of a phase difference between the received signals of the first and the second antenna boards.
A rotating axis 6 is mounted on a center portion of the connecting plate 5. The antenna unit A is pivotally driven about the rotating axis 6 in the elevation direction by an elevation motor 7. The antenna unit A is held on a rotating board 8 by means of a bearing plate 10. A rotating axis 11 of the rotating board 8 is mounted in the housing 1 by means of a bearing 12. A rubber belt 13 having a gear formed thereon is engaged with a peripheral gear of the rotating board 8 and a gear fixed onto a rotating axis of an azimuth motor 14 which is fixedly mounted in the housing 1. The rotating board 8 may rotate at any angle out of 360° in the azimuth direction driven by the azimuth motor 14.
An electric circuit 16 including an RF converter 160 and tuners for broadcast by satellite (BS) is divided into two parts 16a and 16b, each of which is fixedly mounted in a rear surface of each of the first and second antenna boards 3 and 4. An output from the electric circuit 16 is transmitted to external tuners via a rotation coupling antenna 184, and a control signal and electric power to the azimuth motor 14 are transmitted through a slip ring 15. A notch or opening 21 is formed in the rotating board 8 for an end of the second antenna board 4 to be lowered below the rotating board 8 of the housing when the antenna unit A is rotated about the rotating axis 6 by the driving force of the elevation motor 7.
A signal system for driving the antenna unit A is now described. The first antenna board 3 is further divided into two parts. When it is assumed that planar antennas α and β are formed on the first antenna board 3 and a planar antenna γ is formed on the second antenna board, a drive signal for the azimuth direction (in the rotating direction about the axis 11) is obtained from a phase difference between the output signals of the planar antennas α and β formed on the first antenna board 3 and a drive signal for the elevation direction (in the rotating direction about the rotating axis 6) is obtained from a phase difference of a composite signal of the output signals of the planar antenna α and β from an output signal of the planar antenna γ.
Output signals of the planar antennas α, β and γ are supplied to the RF converter 160. The RF converter 160 includes RF amplifiers 161, 162 and 163, mixer and IF amplifiers (intermediate frequency amplifiers) 164, 165 and 166 and a dielectric oscillator 167. Output signals of the three antennas are divided by splitters 171, 172 and 173, respectively, and are simple-combined or in-phase-combined by combiners 181 and 182, respectively, to be supplied to an external tuner through a rotation coupling antenna 184. On the other hand, the output signals of the three antennas divided by the splitters 171, 172 and 173 are supplied to an error signal processing circuit 50 including BS tuners 51, 52 and 53 and an error signal detection circuit 50b to be converted into second intermediate frequency signals (about 403 MHz) in the BS tuners and supplied to the error signal detection circuit 50b.
The error signal detection circuit 50b uses the output signals of the BS tuners 51, 52 and 53 to produce azimuth error signals Asinθ and Acosθ derived from an offset angle θ of a directing direction of the antenna unit A from the incoming direction of the radio waves projected on an azimuth rotation surface and elevation error signals Esinφ and Ecosφ derived from an offset angle φ of the elevation direction from the incoming direction of radio waves. A and E represent an amplitude of the respective error signals. These error signals are converted into digital signals by an A/D converter and then supplied to a drive control circuit (CPU) 60 of the elevation motor 7 and the azimuth motor 14. The drive control circuit 60 calculates an azimuth offset data (Da) and an elevation offset data (De) indicative of correction values of the directing direction of the antenna unit A on the basis of the azimuth error signal and the elevation error signal, and transfers the former to an azimuth motor driver 61 and the latter to an elevation motor driver 62. The drive circuits 61 and 62 for the elevation motor 7 and the azimuth motor 14, respectively, rotate the antenna unit A so as to minimize the error. The BS tuners 51, 52 and 53 are provided with a gain control terminal G for the automatic gain control (AGC), respectively, and control signals are supplied through the terminals from the CPU 60 to control the gains of the tuners.
The amplitude A of the azimuth error signal includes a component due to the elevation offset angle φ and the amplitude E of the elevation error signal includes a component due to the azimuth offset angle θ. However, the amplitude components function equally in the sine azimuth error signal Asinθ and the cosine azimuth error signal Acosθ extracted simultaneously or the sine elevation error signal Esinφ and the cosine elevation error signal Ecosφ extracted simultaneously. A ratio of the sine azimuth error signal Asinθ to the cosine azimuth error signal Acosθ is hereinafter named an azimuth absolute error tanθ as the amplitude A is countervailed, and a ratio of the sine elevation error signal Esinφ to the cosine elevation error signal Ecosφ is hereinafter named an elevation absolute error tanφ as the amplitude E is countervailed.
When the directing direction of the antenna unit A is coincident with the incoming direction of radio waves, the receiving power level becomes maximum. Thus, in the embodiment, a rotation of the phase in the azimuth direction is set as a reference value when a set of the azimuth error signals Acosθ and Asinθ bring a maximum amplitude component, and a rotation of the phase in the elevation is set as a reference value when a set of the elevation error signals Ecosφ and Esinφ brings a maximum amplitude component to specify the phase angles. Further, the phase angles thus obtained are described by numerical data of n+8 bits (where n is an integer) increasing clockwise from the reference value of phase angle 0° described as (1000 . . . 0) shown in FIGS. 4A and 4B. An angle data is extracted from a table recording predetermined values corresponding to possible angles in the range of 90° within one quadrant.
As shown in FIG. 4A, the numerical data of the error signal includes the least significant bit (LSB) to n-th bit representing a phase angle (angle data) in the quadrant up to 90°, (n+1)-th and (n+2)-th bits representing the quadrant (quadrant data), (n+3)-th to (n+7)th bits representing a rotation number (rotation data) of the phase, and a (n+8)-th bit (MSB) representing a rotation direction (polarity data) of the phase. That is, the azimuth offset data Da obtained in the CPU is numerical data of (n+8) bits obtained on the basis of the azimuth error signal and the elevation offset data De is numerical data of (n+8) bits obtained on the basis of the elevation error signal. Accordingly, the motor drivers DRVa 61 and DRVe 62 supplied with these data drive to forwardly or reversely rotate the azimuth motor Ma 14 and the elevation motor Me 7, respectively, at a speed proportional to a deviation of the offset data with (1000 . . . 0) as the reference.
A principle of searching for the satellite in the antenna apparatus of the present invention is now described.
Upon the beginning of the receiving operation or upon cutting off of radio waves interrupted by an obstacle, the output of the tuner is reduced below the threshold level.
The distribution of the received radio waves spreads shaped as a straw hat on the azimuth x elevation plane as shown in FIG. 5. The search of the satellite is equivalent to detection of an apex of the hat shape distribution and is attained by changing the direction of the antenna so that the azimuth and the elevation are varied to obtain the reception intensity of radio waves by the antenna equal to or closest to the apex of the main lobe.
The received signal has two peaks on the main lobe and the side lobe as illustrated in FIG. 5. FIG. 6 shows waveforms on the plane of the azimuth x output at a position of EL=a in FIG. 5. FIG. 7 shows waveforms on the plane of the azimuth x output at a position of EL=b in FIG. 5. The intensity of the received signal is varied as shown in FIGS. 6 and 7 by varying gains of the tuners 51, 52 and 53. Waveforms 2 and 2' of FIGS. 6 and 7 are waveforms in the case where the gains of the tuners 51, 52 and 53 are increased as compared with waveforms 1 and 1'. The main lobe of the waveform 2 of FIG. 6 exceeds a saturation point of the circuit and is saturated.
An actual method of searching for the satellite is now described.
In order to determine an optimum direction of the antenna apparatus rapidly, a rough search is first made as illustrated in FIG. 10 to detect whether the incoming direction of radio waves from the satellite is larger or smaller than the reference elevation angle, and then a fine search in accordance with a "four-step scanning" illustrated in FIG. 9 is made.
The reference elevation angle depends on the latitude of a place where the antenna apparatus is used and the 40th degree of the north latitude is preferably adopted as the reference elevation angle in Japan which spreads from about 23rd degree to 53rd degree of the north latitude.
In the rough search of FIG. 10, scanning lines a and b are provided in positions of +7.5 degree and -7.5 degree with respect to the reference elevation angle of 40th degree.
The rough search is made as follows:
A level of a gain control signal fed back to the gain control terminals G of the tuners 51, 52 and 53 from the CPU 60 is first increased. Consequently, the output levels of the tuners 51, 52 and 53 are increased as a whole as illustrated by the waveform 2 of FIG. 6. Thus, the half-power angle of the received signal is widened and an area exceeding the threshold level SH is also widened. The antenna is rotated maximum 360° along one of the scanning lines a and b nearer to the elevation angle upon cutting off of radio waves to search for a point where the output exceeds the threshold level SH.
In FIG. 5, when it is assumed that the elevation angle EL is fixed to b (EL=b) and the azimuth is varied, the waveform 1' can not exceed the threshold SH as illustrated in FIG. 7 and it is impossible to detect a peak exceeding the threshold SH even if the antenna is rotated by 360° in the azimuth direction. On the contrary, when the gain is increased to obtain waveform 2' illustrated in FIG. 7, the received signal can exceed the threshold SH at the azimuth angle AZ1 of FIG. 7, and accordingly it can be decided that a peak of electric power exists in the vicinity of AZ1. When a point where the output exceeds the threshold level SH can not be detected even if the antenna is rotated up to 360°, the same searching operation is made along the other scanning line. Thus the side with respect to the reference elevation angle and the position or at least the vicinity where the peak of electric power lies can be detected with high probability.
Then, information obtained by the rough search is utilized to make a fine search. In the fine search, as illustrated in FIG. 9(a), a first scanning line is set at an angle of +11.25° with respect to the center of the reference elevation angle 40°, a second scanning line at an angle of +3.75°, a third scanning line at an angle of -3.75°, and a fourth scanning line at an angle of -11.25°. The antenna is rotated in the azimuth direction maintaining the elevation angle at one of the above angles and the fine search is made to detect a point where outputs of the tuners 51, 52 and 53 exceed the threshold level.
Since the half-power angle of the main lobe is usually smaller than 7.5 degrees, the angular difference between the scanning lines is set to 7.5 degrees. This scanning method is hereinafter referred to as the "four-step scanning".
In the fine search, a level of the gain control signal fed back to the gain control terminals G of the tuners 51, 52 and 53 from the CPU 60 is first reduced. Consequently, the output level of the tuners 51, 52 and 53 is reduced as a whole as illustrated by the waveform 1 of FIG. 7. In this state, the fine search using the four-step scanning is made. When the received signal exceeds the threshold SH on the scanning line a during the rough search, that is, when the elevation angle is larger than the reference elevation angle, the scanning is made along the first scanning line with the reduced gain, and then if the main lobe is detected the operation proceeds to a peak detection to be described later. If the main lobe is not detected, the elevation angle is changed to set the scanning line to the second scanning line and another search is carried out. Nevertheless, if the main lobe is not detected even in the second search, the scanning is made along the fourth and third scanning lines, and if the main lobe is detected, the operation proceeds to the peak detection. On the other hand, when the received signal exceeds the threshold SH on the scanning line b during the rough search, that is, when the elevation angle is smaller than the reference value, the scanning is made along the fourth scanning line first with the reduced gain. When the main lobe is not detected in the search, the elevation angle is changed to set the scanning line to the third scanning line and another search is carried out. More particularly, when the threshold SH is exceeded on the scanning line a during the rough search, the azimuth rotation angle is varied in the range of 20° at first in order from the first, second, fourth to third scanning line as shown in FIG. 9(b) to make the search, and if the peak is not detected by the search, the rotation range is successively extended to 60° and 120° to make an additional search. Similarly, when the threshold SH is exceeded on the scanning line b during the rough search, the search is made in order from the fourth, third, first to second scanning line as illustrated in FIG. 9(c). The search is made on the basis of an amplitude data Ran obtained by the mean square value of the sine azimuth error signal Asinθ and the cosine azimuth error signal Acosθ corresponding to the intensity of the received signal.
When the azimuth amplitude data Ran exceeds a threshold THas predetermined for the amplitude data, the scanning operation is stopped and the peak detection illustrated by the flow chart of FIG. 8 is started. The peak detection is made on the basis of the amplitude data but includes a finer control as compared with the above search. In the peak detection, an azimuth toggle counter TCa, an elevation toggle counter TCe are first cleared and past data of the azimuth amplitude Rap and past data of the elevation amplitude Rep are also cleared (step 20). A proper data Da for azimuth offset is supplied to the azimuth motor driver 61 to instruct for the azimuth motor 14 to rotate in the forward direction (step 21). Then, the azimuth amplitude data Ran until that time is evacuated to the past data Rap of the azimuth amplitude data Rap (step 22). Then, the process is in a waiting state until the directing direction in the azimuth rotation plane is slightly changed with a small increment (step 23). The new sine azimuth error signal Asinθ and cosine azimuth error signal Acosθ are read (step 24) to obtain the azimuth amplitude data Ran at this time (step 26), which is compared with the azimuth amplitude data before being changed, that is, the past data Rap (step 27).
At this time, if the directing direction of the antenna unit A approaches the incoming direction of radio waves, the azimuth amplitude data Ran shall be larger than the past data Rap, whereas if the directing direction is distant from the incoming direction, the azimuth amplitude data Ran shall be smaller than the past data Rap (refer to FIG. 9). In the former case, small increments of the directing direction may be repeated in the same direction and increase and decrease of the azimuth amplitude data may be repeatedly detected, while in the latter case it is necessary to reverse the change direction. The LSB of the toggle counter Ca is used for judgment of the change direction. That is, when the past data Rap of the azimuth amplitude is larger than the azimuth amplitude data Ran, small increments in the forward direction are made while the LSB of the toggle counter TCa is "0" and small increments in the reverse direction are made while the LSB is "1" (steps 29, 30 or 29, 21).
As described above, each time the past data Rap becomes larger than the azimuth amplitude data Ran, the toggle counter TCa is incremented by 1, accordingly when the value of the toggle counter TCa is equal to or larger than 3, the direction of the antenna unit has crossed the incoming direction of radio waves in the azimuth rotation plane at least two times and the incoming direction of radio waves is substantially corresponding to the directing direction of the antenna unit A with respect to the azimuth rotation plane. Thus, if the value of the toggle counter TCa is larger than 2 (step 25), the peak detection with respect to the azimuth rotation plane has finished, and then the peak detection with respect to the elevation rotation plane is to be made (steps 31 to 40). The peak detection with respect to the elevation rotation plane is quite the same as the peak detection with respect to the azimuth rotation plane only with reading elevation for azimuth, and accordingly its description being omitted. Detailed description of the peak detection is found in Japanese Patent Unexamined Publication No. 2-250502 filed by the present inventors.
In the of the present invention, the rough search is made within the wide range including the side lobe by increasing the gain of the AGC, while there is a case where a waveform of the main lobe is wide depending on the characteristics of an antenna as shown in FIG. 11. The present invention can be also applied to an apparatus using such an antenna. In this case, the waveform of the main lobe is distorted and a width of the main lobe is enlarged by increasing the gain of the AGC as illustrated by B of FIG. 11, so that a half-power angle of the main lobe is enlarged from A to B. Intervals of scanning lines in the rough search are set to overlap the enlarged half-power angle B, so that the rough search can be made rapidly as compared with a case where intervals of scanning lines are set to overlap the half-power angles A. The fine search following the rough search is the same.
As described above, in the present invention, gain setting means for varying gains for AGC of the tuners is provided, so that upon searching for the satellite the gains are set to a first gain by the gain setting means to perform a rough search and the gains are then reduced to a second gain, lower than the first gain, to perform a fine search. The rough searching method is not limited to the above description.
As described above in detail, according to the present invention, there can be provided the receiving antenna apparatus for receiving broadcast by satellite including automatic tracking means capable of catching the satellite in a short time.
|
A receiving antenna apparatus for receiving broadcast by satellite and adapted for mounting on a mobile body in which radio wave interruption tends to occur by obstacles, attains high-speed automatic tracking function capable of catching the satellite again in a short time just after cutting off of radio waves. In the receiving antenna apparatus, an incoming direction of radio waves is roughly detected to limit a search area and then a gain of the tuners is reduced to a value in the tracking control capable of detecting a peak and confirming a main lobe in accordance with power level of the received signal, so that a narrow and fine search may be made only in the limited search area. The antenna apparatus includes a gain setting device for varying gains of AGC of the tuners. Upon searching for the satellite, gains of the tuners are set to a first gain by the gain setting device to perform the rough search and the gains of the tuners are reduced to a second gain level lower than the first gain to perform the fine search. Thus, a time required to catch the satellite after cutting off of radio waves can be reduced.
| 6
|
BACKGROUND OF THE INVENTION
The present invention is related to the invention described and claimed in U.S. patent application Ser. No. 08/496,504, now U.S. Pat. No. 5,579,829 filed on Jun. 29, 1995, and assigned to the same Assignee as that of the present invention.
The present invention relates generally to the formation of openings in well casings at a subsurface location within an existing well. More specifically, the present invention relates to a tool, system and method for cutting a window through the wall of a well casing at a desired subsurface location within the well with the window having desired dimensions and a desired orientation permitting subsequent drilling of a lateral well bore through the window. The present invention also relates to the provision of subsurface anchoring means that may be installed after the casing is run or may be installed in the casing string as the casing is run to function as an anchoring and orienting mechanism for the window cutting process as well as for subsequent operations conducted after the window is cut.
Formation of a lateral well bore from a main well bore is well known in the prior art. Where the lateral bore is formed from an existing cased well, it is necessary to form an opening through the casing at the point the lateral well is to begin. The equipment used for this process usually includes a whipstock having a slanted guide surface that is used to direct a rotary mill against the casing wall. It is common to begin the process with a small "starting mill" that forms an initial cut used as a guide for a subsequent, larger cut made by a "window mill". Using this procedure necessitates at least two trips into the well, the first for the starting cut and the second for the window cut. Another shortcoming associated with prior art deflecting tools is that commonly used whipstock and mill devices allow the mill to rest against the deflecting guide surface causing the guide surface to be milled along with the casing wall. This destruction of the guide surface shortens the useful life of the deflecting tool.
After cutting the window, drilling equipment is lowered into the well to form the lateral well bore. The whipstock used to initially form the window may also serve to direct the drill bit through the window and into the formation. While the presence of the whipstock assists in directing the drill bit and other equipment through the casing window, its presence presents an obstruction to the casing below the whipstock. Removal of the whipstock to obtain access to the casing below complicates re-entry of equipment or tools into the lateral bore.
BRIEF DESCRIPTION OF THE INVENTION
The tool system and method of the present invention provide a novel single trip technique for forming a subsurface window in a well casing. In a preferred form of the invention, the window is formed and a subsurface anchoring and orienting sleeve is installed in a single trip of the tool into the well. After installation of the anchoring and orienting sleeve and formation of the window, a drilling assembly or other subsurface equipment or tools may be re-engaged with the sleeve to be automatically oriented and anchored relative to the window.
The tool is initially oriented and then anchored at a desired subsurface location within the well casing adjacent an area where a window is to be cut through the casing wall. Anchoring of the tool is accomplished by activating or "setting" hydraulically operated slips that lock against the internal casing wall to prevent downward movement of the tool. Weight is then applied to the tool through the drill string assembly to set weight-set slips that prevent upward movement of the tool. Initiation of the setting procedure with hydraulically set slips reduces the likelihood of premature setting or other setting problems that may occur when mechanically set slips using drag blocks or other restricting devices are employed in the setting mechanism. The hydraulic setting also prepares the tool for subsequent release from an anchoring and orienting sleeve that contains the slips and also contains an orienting arrangement for holding and orienting equipment or tools after the window is formed. When the tool is retrieved, a substantially large central sleeve opening allows access to the well below the sleeve.
The window is formed by cutting multiple longitudinally extending, contacting openings in the casing wall. The individual openings combine to produce a window having a desired circumferential development. An indexing mechanism is employed to move the cutting device of the tool angularly by a desired amount to bring the wall cut into contact with the preceding cut. The indexing mechanism also functions to hold the tool in place while the cut is being formed. The number of cuts and the angular indexing of the cutting device are selected as a function of the circumferential size of the cutting device's cut and the desired window size.
An important feature of the present invention is that the cutting device is supported for movement in the tool such that the cutting action is directed solely to the casing and not against the deflecting surface.
The preferred form of the cutting device of the present invention is a rotary mill that is mounted for movement through the tool by a carriage that permits rotary, longitudinal and radial movement of the cutting device. The carriage rides on a longitudinally extending ramp that slowly advances toward the casing wall and then parallels the casing wall. As the carriage follows the ramp, the mill is slowly moved into contact with the casing wall to begin the cut. As the carriage advances up the ramp, it continues to make an increasingly deeper cut in the casing as it moves longitudinal, finally moving parallel to the casing axis after a full width cut is established. This incremental increase in cutting depth during the initial cutting action assists the mill in starting and maintaining a substantially straight track.
From the foregoing it will be understood that a primary object of the present invention is to provide an apparatus and process for forming a subsurface window in a well casing on a single trip into the well.
Another object of the present invention is to provide a device that forms multiple, adjacent, longitudinal cuts in a casing wall with a single cutting tool so that the cuts combine to form a single window through the casing wall.
Still another object of the present invention is to provide a single trip method for forming a subsurface window in the casing of a well and installing an anchoring and orienting sleeve that is used during the window formation and that also provides an anchoring and orienting mechanism for subsequent well procedures and equipment installation.
An important object of the present invention is to provide a cutting tool that cuts the casing wall without cutting the deflecting tool surface and that may be advanced into increasing cutting engagement with the casing to initiate the cut in a manner to maintain a relatively straight cutting path.
An object of a modified form of the present invention is to employ a coupling having a contoured internal surface in the casing string of a well to subsequently serve as an anchoring and orienting area for the cutting assembly of the present invention while maintaining a full drift opening through the casing.
These and further objects, features and advantages of the present invention become more fully described in the following specification, drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1F are vertical elevations, in six segments, illustrating the tool of the present invention as it is initially being run into position within a well casing;
FIGS. 2A and 2B are vertical sectional views of two segments of the tool of the present invention illustrating the tool being prepared to mill an opening in the surrounding casing wall;
FIGS. 3A and 3B are vertical sectional views of two segments of the tool of the present invention illustrating the mill at the completion of a longitudinal opening cut into the casing;
FIGS. 4A-4C are vertical sectional views of three segments of the tool of the present invention illustrating initial movement of the cutting tool as it is being indexed to a second circumferential position to form a second cut through the casing;
FIGS. 5A-5C are vertical sectional views of three segments of the tool of the present invention illustrating further movement of the indexing mechanism of the present invention as it is manipulated to position the cutting tool for the second cut;
FIG. 6 is a schematic representation of the spline and slot pattern employed in indexing the cutting tool of the present invention for three separate cutting passes;
FIGS. 7A-7C are partial vertical sectional views of three segments of the completed casing window and installed anchoring and orienting sleeve of the present invention;
FIG. 8 is a lateral cross-sectional view of the cutting tool of the present invention taken along the line 8--8 of FIG. 1B;
FIG. 9 is a lateral cross-sectional view of the cutting tool of the present invention taken along the line 9--9 of FIG. 3B;
FIG. 10 is a lateral cross-sectional view illustrating the cutting tool retracted in preparation for a second pass cut;
FIG. 11 is a lateral cross-sectional view illustrating the cutting tool retracted in preparation for a third pass cut;
FIG. 12 is a lateral cross-sectional view taken along the line 12--12 of FIG. 7A illustrating a completed casing window with the cutting assembly retrieved;
FIG. 13 is a perspective assembly view of the cutting tool, carriage mechanism and cutting assembly track of the present invention; and
FIG. 14 is a partial vertical elevation illustrating a coupling in a casing string to be employed for anchoring and orienting the cutting assembly of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The tool of the present invention is indicated generally at 10 in FIG. 1 at a subsurface location within a surrounding well casing 11. A central mandrel 12 connects to a drill string 13 (FIG. 3) which in turn extends to the well surface (not illustrated). As will be hereinafter more fully explained, the drill string 13 is manipulated from the well surface to position and operate the tool 10.
The mandrel 12 extends through a tubular spline housing 14 at the upper end of the tool 10. The spline housing is secured to a tubular slotted mill housing 15 that is in turn connected at its lower end to an index slot mandrel 16. The lower end of the slot mandrel 16 necks down to a cylindrical slot surface section 17 that connects at its end to a mandrel latch section 18. A hydraulic seal sub-assembly 19 connects between the mandrel latch section 18 and a tubular mandrel release collet 20. The release collet 20 includes multiple collet fingers 21 having collet heads 22 that are held in radial recesses 23 in a surrounding mandrel housing 24. A hydraulic piston 20a having a retainer ring 26 at its lower end underlies the collet 20 with the ring 26 underlying the collet heads 22. The lower end of the housing 24 is surrounded by a dog retaining assembly indicated generally at 25 that employs upper and lower sets of Bellville spring washers 26a to urge contoured orienting and anchoring dogs 27 radially outwardly into engagement with slotted and grooved recesses 28 in the internal surface of an anchoring and orienting sleeve section 29. The upper end of the sleeve section 29 is connected to a tubular slip section 30. The slip section 30 carries hydraulically set slips 30a and weight set slips 30b that are used to anchor the slip section to the internal wall of the casing 11 to hold the slip section 30 and attached anchoring and orienting section 29 firmly in position within the casing.
As thus far described, the tool 10 is comprised of four basic tool segments that may be moved longitudinally relative to each other. The first tool segment, herein referred to as the milling segment, is comprised of the central mandrel 12 that carries a cutting mill 31 at its lower end. Splines 12a carried on the mandrel 12 are adapted to be received in slots 32 formed in the spline sleeve 14. (See FIG. 13). When the slots 32 receive the splines 12a, rotation of the mandrel 12 relative to the housing 14 is prevented.
The second basic tool segment, or central segment, is comprised of the spline housing 14, mill housing 15, index slot mandrel 16, mandrel latch section 18, seal sub-assembly 19 and mandrel release collet 20.
The third basic tool segment, or release segment, is comprised of the mandrel housing 24 and dog retaining assembly 25.
The fourth basic tool segment, or anchor segment, is comprised of the anchoring sleeve 29 and the tubular slip section 30.
The tool 10 is run into the casing with the four basic segments fixed longitudinally relative to each other as best illustrated in FIG. 1. This running in configuration holds the slips 30a and 30b and mill 31 in radially retracted positions so that the combined assembly may be moved freely down through the casing 11. Once the tool is at the desired subsurface location within the casing 11, the tool is oriented with conventional orienting techniques so that the mill 30 is directed toward a selected geographic point. The anchor segment is then hydraulically set to hold the tool in place within the casing 11. Setting of the anchor segment is followed by release of temporary holding components that functioned before setting the tool to prevent movement of the tool sections relative to each other. Once released, the milling section may be moved longitudinally and radially to cut the casing wall. Following a cut, the control segment may be moved longitudinally and angularly to index or shift the mill to a new circumferential cutting area along the casing. Following formation of all of the cuts, the release segment may be pulled free of the anchor segment to permit retrieval of the assembly comprised of the milling, control and release segments to the well surface. The anchor segment remains in place to provide an anchoring and orienting area within the casing that functions to receive, anchor and orient tools or other well equipment lowered into the well for additional work or installation of equipment relative to the casing window.
In operation, the assembly 10, as illustrated in FIG. 1, is lowered through the well casing 11 to the desired subsurface location, typically being a point immediately below that at which the casing window is to be formed. When properly positioned at this point, the tool 10 is oriented circumferentially so that the mill 31 is facing a desired geographic point or area. This may typically be a hydrocarbon bearing formation that is laterally offset from the main well bore. Once properly positioned and oriented, the tool is anchored in place within the casing 11 by a sequence of operations commencing with the application of hydrostatic pressure through the drill string 13. The hydrostatic pressure communicates from the drill string through the central mandrel 12, through a flexible fluid line 33, through the index slot mandrel 16, through the seal subassembly 19 and through radial ports 34 into the hydraulic setting structure acting on the slips 30a. The described setting procedure, which is conventional, causes the slips 30a to extend radially outwardly into firm gripping engagement with the internal wall of the casing 11. Once the slips 30a have set, the tool 10 is prevented from moving down the casing. Weight is then applied to the tool 10 through the drill string 13 in a conventional manner to set the slips 30b, which act to prevent upward movement of the tool 10. In a typical installation, the slips 30a are set with an application of hydrostatic pressure of approximately 1500 psi and the slips 30b are set with the application of approximately 10,000 pounds of weight on the tool 10.
Once both slip sections 30a and 30b have been set, the hydrostatic pressure in the drill string is increased to approximately 2,500 psi to shear temporary restraining pins and force the hydraulic piston 20a down through the mandrel release collet 20 as best illustrated in FIG. 2. This downward shift of the piston 20a displaces the retainer ring 26 away from the collet heads 22 to free the collet (and attached central segment) for longitudinal movement relative to the surrounding release segment (mandrel 24) and anchor segment (slip section 30).
Following release of the control segment, the mill segment is released by increasing the amount of weight applied to the tool 10 to approximately 20,000 pounds, severing a temporary retaining shear pin 35 holding the central mandrel 12 to the spline housing 14. This action frees the milling segment to move longitudinally relative to the control segment. After shearing of the pin 35, a re-engageable detent 35a secures the central mandrel 12 to the control segment (housing 14). A force of approximately 4000 pounds is required to separate the mandrel 12 from the detent. The detent is automatically re-engaged with the mandrel 12 each time the spline is moved back to its starting point (illustrated in FIG. 1).
To initiate the first cut, the drill string 13 is lowered sufficiently to displace splines 12a on the mandrel 12 from receiving slots formed in the slot housing 14 to permit rotation of the mill 31. The drill string is then rotated and advanced downwardly to propel the mill 31 along sloped tracks 36 and 37 (see FIG. 13) through a mill housing opening 38 into contact with the surrounding casing wall. The mill 31 is supported between the tracks 36 and 37 by front and rear carriage mounts 39 and 40, respectively, that permit rotary motion of the bit while spacing the bit to prevent it from cutting the underlying mill housing.
The initial rotation of the mill 31 ruptures the hydraulic fluid line 33. As the mill advances along the sloping tracks 36 and 37, it is slowly advanced into engagement with the casing wall to begin the cut with a minimum of offsetting forces that tend to cause the mill to drift in the direction of the cutting rotation. The cut becomes deeper during the initial mill travel, extending through the casing wall and slightly into the cement (not illustrated) or other material surrounding the casing. Once the mill cuts through the casing wall, the tracks direct the mill along a path substantially parallel to the axis of the tool 10 to form the major portion of the longitudinal casing cut which, as will be described, cooperates with subsequent longitudinal cuts to form a window 41 through the casing. The end of the mill cut is reached when the mill carriage mount 39 engages the end of the mill housing opening 38 as indicated in FIG. 3.
The second cut of the mill is accomplished by changing the angular position of the control segment (slot section 17) relative to the anchor segment (sleeve 29). The angular position of the control segment is changed by selectively lowering, raising and rotating the drill string 13 to advance a slot surface pattern 42 (see FIG. 6) formed on the external cylindrical surface of the slot section 17 over splines 43 positioned within a spline sleeve 44 at the upper end of the mandrel housing 24.
With reference to FIG. 6, the slot pattern 42 is configured to produce three separate angular positions of the milling segment (housing 15) relative to the control segment (slot mandrel 16). Each of the three angular positions is selected to be approximately 60° from the adjacent section so that, with a suitably sized mill 31, the three cuts combine to form a window of approximately 180° in circumferential development.
To place the milling segment in its next desired angular position after the first cut, the drill pipe 13 is initially raised until the splines 12a are received within the spline housing latching the detent 35a and then raised further to pull the control segment (slot mandrel 16) up through the release segment (spline sleeve 44). The milling segment is releasably secured to the control segment by spring loaded dogs 45 that mesh with recesses 46 or 47, formed on the mandrel latch section 18. The spring loading is imposed by a set of Bellville springs 48 that cooperate with tapered bearing surfaces to urge the dogs 45 radially inwardly against the mandrel latch section 18. The dogs 45 and recesses 46 and 47 have matching tapered contours that permit the dogs to be displaced longitudinally from the recesses when sufficient longitudinal force is exerted between the two components. In the illustrated form of the tool 10, an upward force of approximately 8,000 pounds is required to displace the dogs 45 upwardly from their engagement with the recess 46 or 47. Because of the contours of the dogs and recesses, a downward force on the control segment of approximately only 2000 pounds is required to displace the dogs 45 downwardly from the recesses 46 or 47.
After the application of the 8000 pound upward force, the milling segment (slot mandrel 16 and slot surface section 17) are free to move up until the recesses 46 and 47 have passed the dogs 45 and a shoulder 42a in slot 1 of the slot pattern engages the splines 43. The shoulder engagement is noted by a change in lifting force in the drill string 13 above the 8000 pound force required to move the two recesses 46 and 47 past the dogs 45. At this shouldering point, the drill string is torqued to the right to shift the lower end of slot 1 over the splines 43 to allow the mill segment to be moved relative to the splines 43 into the relative position illustrated by the dotted line representation 43a of the splines 43. (See FIG. 6). The drill string is then lowered while maintaining a right hand torque so that the slot pattern 42 advances over the splines 43 to move into the relative position indicated by the dotted line spline representation 43b. At this relative position of the spline sleeve 44 and slot pattern section 17, the dogs 45 are landed in the recess 46 to temporarily hold the milling assembly (mill housing 15) fixed relative to the control assembly (housing 24) during the formation of the second mill cut. It will be noted that the longitudinal position of the mill segment is higher when the mill segment is indexed in its second cut (spline in position 43b) to provide a window having a high center top opening.
With the milling segment and control segment thus aligned, the drill string 13 is lowered to release the detent 35a and move the splines 12a out of the spline housing 14. The drill string 13 is then lowered and rotated, as described previously, to cut a second cut in the casing wall to form a partial window as indicated in FIG. 11. Following completion of the second cut, the described sequence of drill pipe movement and torque is repeated to index the tool for the third cut to complete the window 41 as indicated in FIG. 12.
Once the window has been fully cut, the milling segment, control segment and release segment are retrieved to the well surface as a unit. This is effected by exerting an upward pull on the drill string that pulls the dogs 27 free of the anchor recesses 28. An upward force of approximately 25,000 pounds is required to release the dogs. The anchor segment, illustrated in FIG. 7, remains fixed in place below the window 41 to be used at a later time for holding and orienting a whipstock or other subsurface tool or equipment that may be required to drill complete or workover the well. The tubular opening through anchor segment allows ready access to the well casing below the anchor.
FIG. 14 illustrates a modified form of the anchoring assembly, indicated generally at 100, that may be employed with the present invention. The assembly 100 is comprised of a casing coupling 101 having a pattern of slots S and grooves G that are adapted to mate with corresponding contours formed on the dogs 27 of the anchoring segment of the invention. The coupling 101, as more fully described in the related application hereinbefore identified, is placed in the casing string of a well when the well is initially drilled. The pattern and placement of the slots and grooves in the coupling 101 function similarly to those within the anchoring segment (sleeve 29) described in the first form of the invention.
When it becomes desirable to re-enter a well equipped with the coupling 101, the assembly substantially as retrieved from the set anchor segment of the previous embodiment is run into the well and landed in the coupling 101. The advantage of equipping the well with a coupling such as the coupling 101 is that the anchoring and orienting functions required for milling a casing window may be provided with a device that permits a fully open, or full drift, casing.
While the present invention has been described as forming three cuts to create a single window, it will be appreciated that four or five or more such cuts may be used. Also, while a window of 180° degree circumferential development was described, it will be understood that any desired size window may be formed. Similarly, while specific examples of force values required to free, index or otherwise control the formation of the window and the release from the anchor segment, it will be understood that the force values will vary depending on equipment size and other factors.
The foregoing disclosure and description of the invention is illustrative and explanatory thereof. It will be appreciated by those skilled in the art that various changes in the size, shape and materials, as well as in the details of the illustrated construction. The combinations of features and the method steps discussed herein may be made without departing from the spirit of the invention.
|
A single trip tool and method for cutting a subsurface window through a well casing and installing an anchoring and orienting sleeve in the casing adjacent the window for subsequent downhole well procedures and equipment installation. A mill held in position within the casing by a hydraulic and weight-set tubular anchor sleeve is used to cut multiple vertical slots in the casing wall to form a single, large window. An indexing mechanism controls circumferential placement of the mill to ensure contact between adjacent slots. The mill is supported for rotation and longitudinal movement by a carriage mount that advances along dual sloping rails causing the mill to form an increasingly deeper cut during its initial cutting movement. Following formation of the window, the mill is retrieved leaving the anchoring sleeve in place for subsequent well procedures. A second embodiment anchors and orients the cutting assembly with an internally contoured coupling that is part of the casing string.
| 4
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/491,075, filed on Jul. 30, 2003. The disclosure of the above application is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to systems for providing a torque to move an object that needs to be rotated, and more particularly to an energy shuttle apparatus and method that converts linear motion into a rotary motion for providing a torque to a component that is required to be rotated or twisted.
BACKGROUND OF THE INVENTION
[0003] The ability to controllably twist or bend a wing, airfoil or rotorcraft blade, during various phases of flight of an aircraft or rotorcraft, has been a goal of design engineers for some time. The ability to controllably twist or deform a wing, air foil, rotorcraft blade, etc. during various phases of flight can significantly enhance the performance of an aircraft or rotorcraft.
[0004] A major obstacle to implementing actuators or other devices that are designed to twist a wing of an aircraft, a blade of a rotorcraft, etc. is that the actuator or other device used for this purpose must overcome the inherent structural stiffness of the material used to form the wing or rotorcraft blade. This limitation has required that such actuators or other like devices be physically large in relation to the wing or rotorcraft blade which they are associated with, as well as expensive, and further require a significant degree of power to overcome the structural stiffness of the structure which needs to be twisted or flexed.
[0005] Accordingly, there still exists a need in the art for a relatively lightweight, compact apparatus capable of being integrated for use with an air foil, wing, rotorcraft blade, etc. that can twist or deform the air foil, wing or rotorcraft blade as needed, and which further does not require the use of large actuators.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to a system and method for assisting in moving a component. More specifically, the invention relates to an apparatus and method for storing energy and “shuttling” the energy between the apparatus and an airfoil, wing or rotorcraft blade. In one preferred form the present invention is directed to an apparatus which assists in providing a torque to a member used to twist a structure such as a wing, air foil or rotorcraft blade. A biasing member is incorporated which is coupled to a linkage assembly. The linkage assembly is in turn operatively coupled to a member capable of imparting a twisting force to a structure associated with a wing, air foil or rotorcraft blade. The apparatus is assembled with the biasing member in a biased condition (i.e., pre-loaded) such that the apparatus stores sufficient energy to assist in twisting the airfoil, wing or blade, and more specifically to provide virtually the entire torque needed to twist or rotate the wing, airfoil or blade. The apparatus effectively provides a negative spring force to the structure which operates to overcome the inherent structural stiffness of the structure.
[0007] In one preferred implementation the member comprises a torque tube extended within at least a portion of a air foil, wing or rotorcraft blade. A conventional, low power actuator is used to initiate rotational movement of the torque tube and the biasing force stored by the biasing member provides at least a significant portion (or substantially all) of the force required to twist or deform the structure. In effect, the stored energy is transferred (i.e., “shuttled”) to the airfoil, wing or blade to help twist the structure and then transferred back (“shuttled”) to the biasing member when the structure is allowed to return to its unflexed or un-deformed state. This allows a much smaller, lighter weight and less costly actuator to be employed in such applications because the actuator is only required to supply a very small portion of the torque needed to bend or deform the structure with the stored energy in the biasing member being the predominant force used to twist the structure. The biasing member can be “tuned” so that substantially only the aerodynamic load experienced by the structure needs to be overcome by the actuator. The linkage assembly provides the further advantage of being able to rotate the torque tube in opposite rotational directions, which significantly enhances the range of bending or flexing action that can be imparted to the structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0009] FIG. 1 is a side view of an apparatus in accordance with a preferred embodiment of the present invention;
[0010] FIG. 2 is a simplified plan view of a portion of a wing showing the apparatus incorporated in the wing;
[0011] FIG. 3 is a view of the apparatus imparting a torque to a torque tube to twist the wing of FIG. 2 ;
[0012] FIG. 4 is a side view of the tension adjuster;
[0013] FIG. 5 is an end view of the tension adjuster taken in accordance with directional line 5 - 5 in FIG. 4 ;
[0014] FIG. 6 is a side view of the end guide;
[0015] FIG. 7 is a front view of the end guide;
[0016] FIG. 8 is an end view of the spring guide;
[0017] FIG. 9 is a side view of the spring guide taken in accordance with directional line 9 - 9 in FIG. 8 ;
[0018] FIG. 10 is an end view of the end cap of FIG. 1 ;
[0019] FIG. 11 is a side view of the center support;
[0020] FIG. 12 is a front view of the center support taken in accordance with directional line 12 - 12 in FIG. 11 ;
[0021] FIG. 13 is a front end view of the end bearing;
[0022] FIG. 14 is a side view of the end bearing taken in accordance with directional line 14 - 14 in FIG. 13 ;
[0023] FIG. 15 is a rear end view of the end bearing taken in accordance with directional line 15 - 15 in FIG. 14 ;
[0024] FIG. 16 is a plan view of the end link;
[0025] FIG. 17 is a side view of the end link taken in accordance with directional line 17 - 17 in FIG. 16 ;
[0026] FIG. 18 is a side view of the center link;
[0027] FIG. 19 is a plan view of the center link taken in accordance with directional line 19 - 19 in FIG. 18 ;
[0028] FIG. 20 is an end view of the torque tube;
[0029] FIG. 21 is a side view of the torque tube;
[0030] FIG. 22 is an end view of the housing;
[0031] FIG. 23 is a side view of the housing taken in accordance with directional line 23 - 23 in FIG. 22 ;
[0032] FIG. 24 is a cross-sectional side view of the end members secured to the housing;
[0033] FIG. 25 is a plan view of one of the end members;
[0034] FIG. 26 is a side view of the end member of FIG. 25 taken in accordance with directional line 26 - 26 in FIG. 25 ;
[0035] FIG. 27 is a side view of the outer bearing member;
[0036] FIG. 28 is an end view of the outer bearing member taken in accordance with sectional line 28 - 28 in FIG. 27 ;
[0037] FIG. 29 is side view of the inner bearing member;
[0038] FIG. 30 is an end view of the inner bearing member taken in accordance with directional line 30 - 30 in FIG. 29 ;
[0039] FIG. 31 is a plan view of the inner bearing member taken in accordance with directional line 31 - 31 in FIG. 30 ;
[0040] FIG. 32 is a simplified diagram of the apparatus of the present invention to aid in understanding the pertinent formulas dealing with the torque generated by the apparatus;
[0041] FIG. 33 is a graph of the energy stored in the torque tube in relation to the biasing force of the biasing assembly; and
[0042] FIG. 34 is a graph of the energy required to return the torque tube to its position of equilibrium.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0044] Referring to FIG. 1 , there is shown an apparatus 10 in accordance with a preferred embodiment of the present invention. The apparatus is useful for storing energy that can be “shuttled” between it and a structure such as a wing, airfoil, or rotorcraft blade to provide a twisting force (i.e., torque) to assist in twisting the wing, air foil, rotorcraft blade or any other structure requiring a bending or twisting force to be applied thereto. It is anticipated that the apparatus 10 will find significant utility in aircraft and aerospace applications where it is highly desirable to flex or twist a wing, air foil or rotorcraft blade during various phases of flight. However, the apparatus 10 may be adapted for use with virtually any structure that requires that its structural stiffness be overcome during twisting, bending or other movement thereof.
[0045] With reference to FIG. 1 , the apparatus 10 generally includes a first assist assembly 12 , a torque tube assembly 14 , and a second assist assembly 16 which is identical in construction to the first assist assembly 12 . However, it will be appreciated immediately that the present invention 10 can be implemented with only one of the assist assemblies 12 or 14 if desired, but will obviously provide only one-half of the torque that would be provided with both of the assist assemblies 12 and 16 .
[0046] Since assist assemblies 12 and 16 are identical in construction, only the construction of assist assembly 12 will be described. Assist assembly 12 includes a tension adjuster 18 , an end cap 19 , an end guide 20 , a spring guide 22 , a biasing member or assembly 24 , an end bearing 26 , a center support 28 and a linkage assembly 30 . Components 18 - 30 , as well as the torque tube assembly 14 , are disposed within a tubular housing 32 . The housing 32 is supported within or adjacent the structure to be twisted or deformed, as will be explained in greater detail in the following paragraphs.
[0047] Referring to FIGS. 1, 4 and 5 , the tension adjuster is shown in greater detail. The tension adjuster includes a preferably hex shaped shaft 34 on which a suitable wrench can be used to rotate the tension adjuster 18 . The shaft 34 has a bore 35 . A main body 36 has a mid flange 38 and an inside flange 40 . The main body 36 also includes an opening 42 that communicates with bore 35 .
[0048] Referring to FIGS. 1 and 6 - 7 , the end guide 20 can be seen to include a bore 44 . The end guide 20 further includes relief areas 46 for reducing weight. The end guide 20 fits over the outer surface of inside flange 40 of tension adjuster 18 such that the end guide 20 is supported on the inside flange.
[0049] Referring to FIGS. 1 , 8 - 10 , the spring guide 22 includes a body 48 having a flange 50 and a bore 52 . A portion of the body 48 extends within the bore 44 of the end guide 20 and is free to slide therewithin linearly (i.e., horizontally) in the drawing of FIG. 1 .
[0050] With further reference to FIG. 1 , the biasing assembly 24 is illustrated as a plurality of Belleville washers stacked one against another. However, it will be appreciated that a coil spring or other suitable biasing element could just as readily be incorporated. The Belleville washers, however, are particularly advantageous in that they provide a non-linear spring rate. The biasing assembly 24 thus serves to exert a biasing force that tends to urge the spring guide 22 to the right in the drawing of FIG. 1 .
[0051] Referring to FIGS. 1 and 10 , the end cap 19 includes a threaded bore 54 and a threaded internal recess 56 . The threaded internal recess 56 fits over a threaded outer end 58 of the housing 32 to affix the end cap 19 to an end of the housing 32 . The threaded bore 54 receives the threaded main body 36 of the tension adjuster 18 . The position of the tension adjuster 18 can thus be adjusted by rotating with a suitable tool the hex shaped shaft 34 , which causes the end guide 20 to be urged over the spring guide 22 which compresses the biasing assembly 24 . In this manner, the biasing force exerted against the flange 50 of the spring guide can be adjusted.
[0052] Referring to FIGS. 11 and 12 , the center support 28 can be seen to include a main body 60 having a protruding portion 62 . A bore 64 extends through the main body 60 and portion 62 . A plurality of holes 66 are preferably provided for weight reduction.
[0053] Referring to FIGS. 13-15 , the end bearing 26 can be seen. End bearing 26 includes a shaft 70 extending from a body 68 . A mounting portion 71 having a bore 72 is also formed to extend from the body 68 . A hole 73 extends through the mounting portion 71 .
[0054] With further reference to FIGS. 1 and 13 - 15 , the shaft 70 of the end bearing 26 extends into the bore 52 of the spring guide 22 , while the body 68 extends within the bore 64 of the center support 28 .
[0055] Referring to FIGS. 16 and 17 , an end link 74 associated with the linkage assembly 30 of FIG. 1 can be seen in greater detail. The end link 74 comprises an H-shaped component having arms 76 which include openings 78 and 80 formed therein. Openings 78 are aligned to receive a dowel pin 80 ( FIG. 1 ) for coupling the end link 74 to the mounting portion 71 of the end bearing 26 . Thus, the end link 76 is free to pivot about the mounting portion 71 .
[0056] With reference to FIGS. 1, 18 and 19 , a portion of the torque tube assembly 14 can be seen in the form of a center link 82 . The center link 82 includes a hex-shaped opening 84 and a pair of bores 86 on opposite sides of the hex-shaped opening 84 . One of the bores 86 fits between one pair of the arms 76 of the end link 74 and is held therein by a dowel pin 88 ( FIG. 1 ) that extends through openings 80 ( FIG. 16 ) to pivotally couple the center link 82 to the end link 74 . The other bore 86 is identically coupled to the end 74 link of the second assist assembly 16 .
[0057] Referring to FIGS. 20 and 21 , a torque tube 90 associated with the torque tube assembly 14 is shown. Torque tube 90 includes a hex-shaped outer surface and a bore 92 formed to reduce the weight of the torque tube 90 . The torque tube 90 is slidably received within the hex-shaped opening 84 of the center link 82 . Referring briefly to FIG. 1 , the torque tube 90 also extends out through an opening 94 in the housing 32 . Thus, the torque tube 94 extends normal to the direction of motion of the end bearing 26 .
[0058] Referring now to FIGS. 22 and 23 , the housing 32 will be described in greater detail. In addition to the opening 94 , the housing 32 includes an inner bore 96 extending entirely through its length with a reduced diameter section 98 along a mid portion thereof. Reduced diameter area 98 thus forms a pair of steps 100 internal to the housing 32 . Each step 100 abuts one of the center supports 28 of the apparatus 10 . End guide 20 ( FIG. 1 ) is further dimensioned to fit within bore 96 so as to be able to move slideably within the bore 96 . On opposite sides of the bore 94 are a pair of openings 102 . Another pair of openings 104 are provided outside of openings 102 . Still another plurality of bore openings 106 are provided about the opening 94 . Openings 102 , 104 and 106 all extend through to the back (i.e., hidden from view) side of housing 32 so as to allow fastening elements such as dowel pins or threaded fasteners to extend entirely through the housing 32 .
[0059] Referring now to FIGS. 24-26 , the use of a pair of end members 108 can be seen. In FIG. 24 , the end members 108 are shown secured to the housing 32 . End member 108 essentially forms a support to assist in holding the torque tube 90 and to prevent “bowing” of the torque tube in response to torque applied by the linkage assembly 30 . The end member 108 is shown in detail in FIGS. 25 and 26 and includes face portions 110 which each include an opening 112 . Dowel pins or other like securing members (not shown) extend through the openings 112 and are used to secure the face portions 110 to the outer surface of the housing 32 perpendicularly to the housing. The end member 108 further includes a bore 114 which extends through the end member. A reduced diameter portion 116 ( FIG. 26 ) of the bore 114 forms an internal circumferential shoulder. Holes 116 are formed on opposite sides of bore 114 and align with openings 102 in the housing 32 shown in FIG. 23 . Dowel pins or like elements (not shown) extend through holes 116 and through openings 102 in the housing 32 to help secure the end member to the housing 32 .
[0060] Referring now to FIGS. 27-30 , an outer bearing member 120 ( FIGS. 27 and 28 ) and an inner bearing member 122 ( FIGS. 29-31 ) are shown. The outer bearing member 120 includes a body 124 and a flange 126 . Body 124 includes an opening 128 extending therethrough. The inner bearing member 122 ( FIGS. 29-31 ) includes a neck 130 and a body 132 . A bore 134 extends through the length of the inner bearing member 122 and a threaded set screw opening 136 opens into the bore 134 . Neck 130 fits within the bore 128 of the outer bearing member 120 and the body 132 of the inner bearing member 122 abuts the flange 126 of the outer bearing member 120 as shown in FIG. 24 . The bore 134 is further hex-shaped, as seen in FIG. 30 . This hex-shaped bore 134 receives the torque tube 90 therethrough and thus provides support, in combination with the end member 108 , to prevent bowing of the torque tube.
[0061] One preferred implementation of the apparatus 10 is shown in FIG. 2 in simplified form. The torque tube 90 extends within a rotorcraft blade 138 from approximately a root portion 140 of the blade to a tip portion 142 thereof. A suitable supporting structure 144 is disposed within the blade 138 at the tip portion 142 to affix the outermost end 90 a of the torque tube 90 to the blade 138 . A bearing assembly 146 is disposed within the blade 138 near the root portion 140 . The housing 32 is also secured to an interior area 146 of the blade 138 . Alternatively, the housing 138 can be secured to spars or other structural elements inside a wing or airfoil. An actuator 148 is mechanically coupled to the torque tube 90 and is used to initiate rotational movement of the torque tube 90 . However, due to the significant mechanical energy stored by the biasing assemblies 24 , the actuator 148 is able to rotate the torque tube 90 using only a small fraction of the force that would otherwise be required from the actuator 148 . Put differently, the apparatus 10 provides the great majority of the mechanical energy (i.e., torque) required to twist the blade 138 due to the negative spring force experienced by the blade 138 . In practice, the apparatus 10 essentially “shuttles” energy between the blade 138 and biasing assembly 24 . When the blade 138 is in its twisted state, the blade is storing the energy that was previously stored in the apparatus 10 . When the actuator 148 returns the torque tube 90 to its initial position (i.e., to de-flex the blade 138 ), the energy in the blade 138 is transferred back to the apparatus 10 . The apparatus 10 thus provides substantially a “zero stiffness” at the root portion 140 of the blade 90 that allows the blade 138 to twist with only a very small force from the external actuator 148 .
[0062] With further reference to FIG. 1 , the apparatus 10 is assembled such that the biasing assemblies 24 are under compression (i.e., preloaded) when the torque tube 90 is in the position shown in FIG. 3 . Thus, the linkage assemblies 30 will each have three points of equilibrium, one being represented by the position of the coupling assemblies 30 in FIG. 3 , one by the position of the linkage assemblies in FIG. 3 , and one where the torque tube 90 has been rotated slightly clockwise from the orientation shown in FIG. 3 . The coupling assemblies 30 are thus free to move the torque tube 90 either clockwise or counterclockwise in the drawings of FIGS. 1 and 3 , and the position of the linkage assembly 30 in FIG. 1 represents rotation of the torque tube in the counterclockwise direction. Once the actuator 148 ( FIG. 2 ) applies a very small force to the torque tube 90 , the biasing force provided by the biasing assemblies 24 immediately assists in rotating the torque tube 90 either clockwise or counterclockwise depending upon the movement of the actuator 148 . With the linkage assemblies 30 in the position of equilibrium shown in FIG. 3 , only a very small force is required from actuator 148 to hold the torque tube 90 stationary. However, as described above, rotation of the torque tube in either the clockwise or counterclockwise directions (relative to FIGS. 1 and 3 ) requires only a very small force from the actuator 148 . In practice, the reduction of torque required by the actuator 148 can be up to an order of {fraction (1/1000)} of the torque that would otherwise be required to twist the blade 138 .
[0063] Referring now to FIGS. 32-34 , the force required to move the torque rod 90 and the energy required to return the torque rod to its initial position of equilibrium will be described in connection with several formulas. The torque provided by each linkage assembly 30 to the torque tube 90 can be expressed by the following formula:
T SES-to-Ptt =2 *L*F spring *sin (Θ Ptt ) Equation 1
[0064] Where: T SES-to-Ptt is the torque applied to the torque tube 90 .
[0065] The change in length of the biasing assembly (i.e., spring) can be represented by the following formula:
δ X =2 *L (1−cos (Θ Ptt )) Equation 2
[0066] The force needed to move the biasing assemblies from one stable position to the other is represented by:
Equation 3 : F min = T Ptt - max 2 * L * sin ( Θ Ptt - max )
[0067] Referring to FIG. 33 , graph 150 illustrates that the energy stored by the torque tube 90 is essentially equal to the energy provided by the baising assemblies 24 .
[0068] Referring to FIG. 34 , the energy required to return the torque tube 90 to its initial position of equilibrium (shown in FIG. 3 ) is represented by portion 154 of graph 152 .
[0069] From the foregoing, then, it will be appreciated that the apparatus 10 provides a means for dramatically reducing the force needed by an actuator to twist or bend an air foil, wing, rotorcraft blade or any other object that requires a bending or twisting force to be applied thereto during its operation.
[0070] While various preferred embodiments have been described, those skilled in the art will recognize modifications or variations which might be made without departing from the inventive concept. The examples illustrate the invention and are not intended to limit it. Therefore, the description and claims should be interpreted liberally with only such limitation as is necessary in view of the pertinent prior art.
|
An apparatus and method for providing a torque to an external member to assist in twisting or deforming the external member. In one implementation the apparatus is useful for providing a force to a torque tube to assist in rotating, bending or twisting a wing, an airfoil, or a rotorcraft blade. The apparatus includes at least one biasing member which provides a biasing force to a linkage assembly, where the linkage assembly is pivotally coupled to a torque tube. The torque tube is fixedly coupled to the structure which needs to be bent, twisted or flexed. The energy stored in the biasing member provides the great majority of mechanical force required to rotate the torque tube and bend, twist or deform the structure when the structure is urged back into an unflexed or un-deformed state, the energy stored in the structure is transferred back to the apparatus. Thus, an actuator that would normally be employed for this purpose can be made much smaller, lighter and less expensive due to the significant mechanical energy provided by the apparatus.
| 8
|
BACKGROUND OF THE INVENTION
The present invention relates to fluorine-containing bisphenols, their preparation, some precursors and intermediates of this preparation, and the use of the fluorine-containing bisphenols as starting materials for the production of liquid crystals, polymers and flame retardants.
Particular fluorine-containing bisphenols are already known as starting materials for the production of liquid crystals (Polym. Mater. Sci. Eng., 1996, 74, 133-134) or as monomers for polymerization (Fluoro-polymers, 1999, 1, 127-150), for example for preparing polycarbonate (JP 05170892 A2), polyethers (JP 2000273166 A2), or polyesters (Polymer, 1997, 38, 3669-3676). It is also known that in the case of liquid crystals it is advantageous for these to have a linear molecular structure (C. Weygand, “Chemische Morphologie der Flüssigkeiten”, Handbuch und Jahrbuch der chemischen Physik, Volume 2, section 3c, Leipzig, Akadem. Verlagsges. 1941; H. -G. Elias, Makromoleküle, 5 th edition, Volume 1, chapter 20, section 20.1.2, Hüthig & Wepf Verlag, Basle 1990).
J. Gen. Chem. USSR (Engl. Transl.), 1965, 35, 1616-1623, discloses that various 1,2-di(4-halophenyl)tetrachloroethanes (B) can be prepared by cross-coupling of 4-halobenzotrichlorides (A) by means of copper in pyridine. In addition to the desired 1,2-di(4-halophenyl)tetrachloroethanes of the formula (B), this process also gives significant amounts of 1,2-di(4-halophenyl)dichloroethylenes of the formula (C). A disadvantage is that these compounds of the formula (C) cannot be fluorinated directly to form the corresponding 1,2-di(4-halophenyl)tetrafluoroethanes, which leads to costly losses in yield.
According to J. Gen. Chem. USSR (Engl. Transl.), 1965, 35, 1616-1623, fluorination of 1,2-di(4-halophenyl)tetrachloroethane of the formula (B) to 1,2-di(4-halophenyl)tetrafluoroethane (C) is possible only by using the highly toxic and expensive antimony(III) fluoride and a catalyst at high temperatures.
U.S. Pat. No. 4,168,388 discloses a process for preparing 2-, 3-, and 4-trifluoromethylphenol from the corresponding 2-, 3-, and 4-trifluoromethylchlorobenzene. It has the disadvantage that sodium hydride, which ignites readily and reacts vigorously with water, is used as base. In addition, it has been found that the solvent N,N-dimethylacetamide that is used decomposes to form the corrosive N,N-dimethylamine under the reaction conditions described. This prevents recycling of the solvent and makes the process expensive.
Due to the increasing demand for liquid crystals, it is an object of the present invention to provide new fluorine-containing bifunctional compounds having a linear molecular structure.
SUMMARY OF THE INVENTION
This object is achieved with 1,2-di(4-hydroxyaryl)tetrafluoroethanes of the general formula (I)
wherein R are each, independently of one another, hydrogen, F, Cl, Br, I, CN, COOR 2 , C 1 -C 4 -alkyl, C 1 -C 4 -alkoxy, C 1 -C 4 -alkylthio, C 1 -C 4 -perfluoroalkyl, C 1 -C 4 -perfluoroalkoxy, C 1 -C 4 -perfluoroalkylthio, C 1 -C 4 -polyfluoroalkyl, C 1 -C 4 -polyfluoroalkoxy, or C 1 -C 4 -polyfluoroalkylthio, R 2 is C 1 -C 4 -alkyl, and n is an integer from 0 to 4.
DETAILED DESCRIPTION OF THE INVENTION
Preference is given to compounds of the general formula (I) in which
R are each, independently of one another, hydrogen, F, Cl, Br, methyl, methoxy, trifluoromethyl, or trifluoromethoxy, and n is 0 or 1.
As compounds of the general formula (I), particular preference is given to 1,2-di(4-hydroxyphenyl)tetrafluoroethane, 1,2-di(3-chloro-4-hydroxyphenyl)tetrafluoroethane, 1,2-di(3-fluoro-4-hydroxyphenyl)tetrafluoroethane, 1,2-di(3-bromo-4-hydroxyphenyl)tetrafluoroethane, and 1,2-di(3-methyl-4-hydroxyphenyl)tetrafluoroethane.
The invention also provides a process for preparing the compounds of the general formula (I) comprising subjecting to an ether cleavage compounds of the general formula (VI)
where R 3 and R 4 are identical or different and are each benzyl, substituted benzyl (preferably 1-(C 1 -C 4 -alkyl)benzyl), benzhydryl, substituted benzhydryl, isopropyl, tert-butyl, or cyclohexyl, and R and n are as defined in the general formula (I).
The ether cleavage of these 1,2-di(4-alkoxyphenyl)tetrafluoroethanes of the formula (VI) is carried out either by a hydrogenation or a cleavage in acid medium. When R 3 and/or R 4 are a benzyl radical or a substituted benzyl radical, hydrogenation has been found to be particularly useful, whereas cleavage in acid medium is the preferred variant for all other meanings of R 3 and R 4 . Both the hydrogenation and the cleavage in acid medium can be carried out by methods known in the art. For the cleavage in acid medium, use is usually made of aqueous acids such as HCl, HBr, H 2 SO 4 , acetic acid, or phosphoric acid. The hydrogenation is carried out using hydrogen and conventional hydrogenation catalysts such as supported or unsupported noble metal catalysts. For example, palladium on activated carbon in an organic solvent such as ethanol is suitable.
The compounds of the general formula (VI) have not hitherto been known. The invention therefore also provides the compounds of the general formula (VI)
where R 3 and R 4 are identical or different and are each benzyl, substituted benzyl (preferably 1-(C 1 -C 4 -alkyl)benzyl), benzhydryl, substituted benzhydryl, isopropyl, tert-butyl, or cyclohexyl, and R and n are as defined in the general formula (I).
The compounds of the general formula (VI) can be obtained by etherification using the appropriate alcohols.
The invention therefore additionally provides a process for preparing compounds of the general formula (VI) comprising reacting compounds of the general formula (V)
where X is a halogen or pseudohalogen and R and n are as defined for the general formula (I),
with an alcohol of the formula R 3 OH and/or an alcohol of the formula R 4 OH, where R 3 and R 4 are as defined for the general formula (VI). In this process, preference is given to using compounds of the general formula (V) in which X is fluorine or chlorine. As alcohol, preference is given to using benzyl alcohol.
This reaction of the 1,2-di(4-halophenyl)tetrafluoroethane of the general formula (V) to form the 1,2-di(4-alkoxyphenyl)tetrafluoroethane of the general formula (VI) is usually carried out in the presence of an inorganic base in a polar aprotic solvent.
The inorganic base can be, for example, a hydroxide, carbonate, hydrogen sulfate, sulfate, hydrogen phosphate, or phosphate of an alkali metal or alkaline earth metal. Preference is given to using potassium hydroxide.
The polar aprotic solvent can, according to the invention, be an amide such as N,N-dimethylacetamide or N-methylpyrrolidone, a sulfoxide such as dimethyl sulfoxide, a sulfone such as tetramethylene sulfone, or a nitrile such as acetonitrile. Preference is given to using N-methylpyrrolidone. The reaction can, if desired, be carried out in the presence of water.
At the end of the reaction, some or all of the solvent can be recovered by distillation (possibly as a mixture with the water formed in the reaction). Aqueous N-methylpyrrolidone can, for example, be reused a number of times in further batches of this process step, without drying being necessary. Thus, when using potassium hydroxide as base, the waste products of this reaction can be restricted to potassium chloride.
After the reaction is complete and the solvent has been distilled off, the product obtained in this way can be purified by, for example, recrystallization or stirring in a suitable solvent, filtration, and drying.
The compounds of the general formula (V) can be prepared by fluorination of the corresponding chlorinated compounds.
Accordingly, the invention further provides a process for preparing compounds of the general formula (V) comprising reacting compounds of the general formula (III)
with anhydrous hydrofluoric acid.
Here, use is usually made of from 4 to 50 mol of anhydrous hydrofluoric acid per mol of compound (III). The material that is commercially available under the name “anhydrous hydrofluoric acid” is sufficiently free of water for this purpose.
The fluorination can, for example, be carried out at temperatures of 0 to 180° C. and a pressure in the range 1 to 50 bar. Preference is given to temperatures of 10 to 160° C. and a pressure of 10 to 30 bar. If appropriate, the reaction is carried out in the presence of a catalyst and/or an inert solvent. Examples of catalysts that can be used are boron trifluoride, titanium tetrachloride, and antimony pentachloride and pentafluoride. Dichloromethane has been found to be useful as solvent.
It is possible for the anhydrous hydrofluoric acid to be placed in a reaction vessel and the compound (III) to be added, or the procedure can be reversed. It is advantageous to combine the hydrofluoric acid and the compound (III) at relatively low temperatures within the abovementioned temperature ranges (e.g., up to 50° C.) and then to increase the temperature stepwise. If desired, the excess anhydrous hydrofluoric acid can be recovered virtually completely by distillation.
After the reaction is complete and the excess anhydrous hydrofluoric acid has been distilled off, the reaction mixture can be recrystallized or admixed with a suitable solvent (e.g., dichloromethane). In this form of work-up, the organic phase is subsequently admixed with activated carbon and/or an alkali metal fluoride, filtered and evaporated or subjected to an aqueous work-up. The resulting 1,2-di(4-halophenyl)tetrafluoroethane product of the general formula (V) can be purified by, for example, recrystallization or stirring in a suitable solvent, filtration, and drying.
This process differs from the process known from J. Gen. Chem. USSR (Engl. Transl.), 1965, 35, 1616-1623, in that hydrofluoric acid is used in place of large amounts of antimony trifluoride and antimony trifluoride is at most optionally added in very small amounts as catalyst. This makes it possible for the process to be carried out significantly more simply in terms of safety precautions and in an economically attractive manner.
The compounds of the general formula (III) can be prepared by reaction of benzotrichlorides of the general formula (II)
where R and n are as defined for the general formula (I), and X is a halogen or pseudohalogen, in the presence of copper and in a tertiary amine as solvent.
This reaction is a cross-coupling of the benzotrichlorides of the general formula (II). Pyridine is preferably used as solvent.
Preference is given to using benzotrichlorides of the general formula (I) in which X is fluorine, chlorine, or nitro. Particular preference is given to benzotrichlorides of the general formula (I) in which X is fluorine or chlorine. In particular, use is made of 4-fluorobenzotrichloride, 4-chlorobenzotrichloride, 3,4-dichlorobenzotrichloride, or 3-trifluoromethyl-4-chlorobenzotrichloride.
The copper can be used in the form of powder or turnings. The reaction is carried out using a molar ratio of copper to benzotrichloride of the general formula (II) of (0.4 to 5):1, preferably (0.4 to 1):1, and particularly preferably 0.5:1. The reaction temperature is usually in the range from 0 to 115° C. The reaction is preferably carried out in the range from 40 to 80° C.
In this cross-coupling, the benzotrichlorides of the general formula (II) form a reaction mixture that contains 1,2-di(4-halophenyl)tetrachloroethanes of the general formula (III)
and possibly 1,2-di(4-halophenyl)dichloroethylenes of the general formula (IV)
The work-up of this mixture can be carried out, for example, by pouring it into ice water, filtering the mixture, slurrying the precipitate with water, washing the precipitate free of base (e.g., with aqueous hydrogen chloride solution), filtering it off, and drying it. If appropriate, the product mixture obtained in this way can be purified by washing with an inert solvent (e.g., cyclohexane or methanol) or by recrystallization. However, other known methods can also be utilized for the work-up.
The cross-coupling of the first step of the process of the invention may be followed by a chlorination of the resulting product mixture. By means of this chlorination, any 1,2-di(4-halophenyl)dichloroethylenes of the general formula (IV) present in the reaction mixture can be converted into the desired 1,2-di(4-halophenyl)tetrachloroethanes of the formula (III).
For this purpose, the crude reaction mixture from the cross-coupling, the evaporated residue after washing with an inert solvent or the evaporated mother liquor after crystallization can be chlorinated to obtain the compounds of the formula (III) in high yield and purity. The chlorination of the mixture in a suitable solvent (preferably chloroform, chlorobenzene, or chlorobenzotrichloride) is carried out by methods of the prior art. The product obtained in this way can be purified by, for example, recrystallization or stirring in a suitable solvent, filtration, and drying.
The invention further provides the compounds of the general formula (IV)
where X is fluorine, and R and n are as defined for the general formula (I).
The compounds of the general formula (IV) can be isolated from the product mixture of (III) and (IV) by, for example, distillation.
In a preferred embodiment, the preparation of the compounds of the general formula (I) is carried out by means of the following process sequence:
(1) a benzotrichloride of the general formula (II) is reacted in the presence of copper and in a tertiary amine as solvent, (2) a reaction with anhydrous hydrofluoric acid is subsequently carried out, (3) an etherification with one or more alcohols of the formula R 3 OH and/or R 4 OH is then carried out, and (4) finally, an ether cleavage is carried out to give the compounds of the general formula (I).
This process for preparing the compounds of the general formula (I) gives high yields, uses readily available starting materials, and forms small amounts of waste products.
The invention additionally provides for the use of compounds of the general formula (I) as monomers for preparing polymers (preferably polyesters, polyethers, or polycarbonates) and as starting materials for producing liquid crystals or flame retardants.
The following examples further illustrate details for the preparation and use of the compounds of this invention. The invention, which is set forth in the foregoing disclosure, is not to be limited either in spirit or scope by these examples. Those skilled in the art will readily understand that known variations of the conditions and processes of the following preparative procedures can be used to prepare these compounds. Unless otherwise noted, all temperatures are degrees Celsius and all percentages are percentages by weight.
EXAMPLES
Example 1
Reaction Using 4-fluorobenzotrichloride
3700 g of 4-fluorobenzotrichloride together with 14 liters of pyridine were placed in a reaction vessel and, at 65° C., 565 g of copper powder were added a little at a time over a period of 6.5 hours. The mixture was stirred for 16 hours at 65-70° C. A further 100 g of copper powder were added over a period of 1 hour, and the mixture was stirred at 65-70° C. for another 4 hours. The cooled reaction mixture was subsequently poured into 60 liters of ice water, stirred, and filtered with suction. The precipitate was slurried with water, acidified using 1N hydrogen chloride solution, and filtered off with suction, washed with water, and dried at 60° C. in a drying oven.
This gave 2660 g of 1,2-di(4-fluorophenyl)tetrachloroethane in a purity of 84% (GC-% by area), corresponding to a yield of 72% of theory.
To purify the solid further, it was washed twice with 2 liters of cyclohexane and once again filtered off with suction. This gave 1928 g of 1,2-di(4-fluorophenyl)tetrachloroethane as a white solid having a melting point of 128-130° C. This corresponds to a yield of 62% of theory.
Example 2
Reaction Using 4-chlorobenzotrichloride
920 g of 4-chlorobenzotrichloride together with 3200 ml of pyridine were placed in a reaction vessel and, at 65-70° C., 128 g of copper powder were added a little at a time. The mixture was stirred at 70° C. for 19 hours. The cooled reaction mixture was subsequently poured into 15 liters of ice water, stirred, and filtered with suction. The precipitate was slurried with water, acidified using 1N hydrogen chloride solution, and filtered off with suction, washed with water, and dried at 60° C. in a drying oven.
This gave 587 g of 1,2-di(4-chlorophenyl)tetrachloroethane as a white solid having a melting point of 180-187° C. This corresponds to a yield of 75% of theory.
Example 3
Reaction Using 3,4-dichlorobenzotrichloride
794 g of 3,4-dichlorobenzotrichloride together with 2400 ml of pyridine were placed in a reaction vessel and 96 g of copper powder were added at room temperature. The mixture was stirred at 65-70° C. for 17 hours. The cooled reaction mixture was subsequently poured into 10 liters of ice water, stirred, and filtered with suction. The precipitate was slurried with water, acidified using 1N hydrogen chloride solution, and filtered off with suction, washed with water, and dried at 60° C. in a drying oven. The resulting solid was recrystallized from toluene.
This gave 305 g of 1,2-di(3,4-dichlorophenyl)tetrachloroethane as a white solid having a melting point of 197-198° C. This corresponds to a yield of 44% of theory.
Example 4
Reaction Using 3-trifluoromethyl-4-chlorobenzotrichloride
The procedure of Example 3 was repeated using 3-trifluoromethyl-4-chlorobenzotrichloride to give 1,2-di(3-trifluoromethyl-4-chlorophenyl)tetrachloroethane in a yield of 63%.
Example 5
Subsequent Chlorination
4187 g of a mixture of 1,2-di(4-fluorophenyl)dichloroethylene (65%) and 1,2-di(4-fluorophenyl)tetrachloroethane (31%) together with 10.5 liters of chloroform were placed in a reaction vessel. Chlorine gas was passed through the solution, and at the same time the reaction mixture was irradiated at a wavelength of 254 nm and the temperature was increased to 60° C. The mixture was photochlorinated six times for 7-8 hours each time under these conditions. Nitrogen was then passed through the cooled reaction mixture and the mixture was subsequently evaporated.
This gives 4580 g of 1,2-di(4-fluorophenyl)tetrachloroethane in a purity of 87% (GC-% by area), corresponding to a yield of 87% of theory.
To purify the solid further, it was washed twice with cyclohexane and once again filtered off with suction.
This gave 3280 g of 1,2-di(4-fluorophenyl)tetrachloroethane in a purity of 98.6% (GC-% by area) as a white solid. This corresponds to a yield of 71% of theory.
Example 6
Fluorination Using Anhydrous Hydrofluoric Acid
600 ml of anhydrous hydrofluoric acid were placed in a stainless steel autoclave at room temperature. 571 g of 1,2-di(4-fluorophenyl)tetrachloroethane were subsequently added. The temperature was increased stepwise to 146° C. and the hydrogen chloride formed was released at 10-35 bar via a reflux condenser (−15° C.). After HCl gas evolution had ceased, the autoclave was depressurized to atmospheric pressure and the excess hydrofluoric acid was distilled off. The residue was dissolved in dichloromethane, admixed with activated carbon, and then filtered. The filtrate was evaporated and then distilled at 16 mbar (boiling point at 16 mbar: 125-126° C.).
This gave 370 g of 1,2-di(4-fluorophenyl)tetrafluoroethane as a white solid having a melting point of 96-97° C. This corresponds to a yield of 80% of theory.
Example 7
Fluorination Using Anhydrous Hydrofluoric Acid
1000 ml of anhydrous hydrofluoric acid and 25 ml of antimony(V) chloride were placed in a stainless steel autoclave at room temperature. 1157 g of 1,2-di(4-chlorophenyl)tetrachloroethane were subsequently added. In a manner analogous to Example 5, the temperature was increased stepwise to 140° C. After HCl gas evolution had ceased, the autoclave was depressurized and the excess hydrofluoric acid was distilled off. The residue was recrystallized from petroleum ether.
This gave 467 g of 1,2-di(4-chlorophenyl)tetrafluoroethane as a white solid having a melting point of 88-90° C. This corresponds to a yield of 49% of theory.
Example 8
Fluorination Using Anhydrous Hydrofluoric Acid
500 ml of anhydrous hydrofluoric acid and 5 ml of antimony(V) chloride were placed in a stainless steel autoclave at room temperature. 229 g of 1,2-di(3,4-dichlorophenyl)tetrachloroethane were subsequently added. The temperature was increased stepwise to 146° C. After HCl gas evolution had ceased, the autoclave was depressurized and the excess hydrofluoric acid was distilled off. The residue was taken up in toluene, admixed with activated carbon and sodium fluoride, and then filtered. The resulting filtrate was evaporated and then recrystallized from methanol.
This gave 467 g of 1,2-di(3,4-dichlorophenyl)tetrafluoroethane as a white solid having a melting point of 105-107° C. This corresponds to a yield of 49% of theory.
1 H-NMR (d 6 -DMSO, 400 MHz): [δ in ppm] 7.67 (2H, d, J 8.4 Hz), 7.65 (2H, d, J 2.2 Hz), 7.40 (2H, dd, J 8.4 and 2.2 Hz)
19 F-NMR (d 6 -DMSO, 376 MHz): [δ in ppm]−111 (4F, s)
MS (EI) 392 (10%) [M + ], 195 (100) [Cl 2 C 6 H 3 —CF 2 + ]
Example 9
Fluorination Using Anhydrous Hydrofluoric Acid
1000 ml of anhydrous hydrofluoric acid and 30 ml of antimony(V) chloride were placed in a stainless steel autoclave at room temperature. 350 g of 1,2-di(3-trifluoromethyl-4-chlorophenyl)tetrachloroethane were subsequently added. The autoclave was pressurized with nitrogen, the temperature was increased stepwise to 120° C., and the hydrogen chloride formed was released at 10-35 bar via a reflux condenser (−15° C.). After 3 hours, the evolution of HCl gas had ceased, and the autoclave was depressurized and the excess hydrofluoric acid was distilled off at a pressure down to 100 mbar. The residue was poured into water, and the solid was filtered off with suction and dried in a drying oven.
This gave 275 g of 1,2-di(3-trifluoromethyl-4-chlorophenyl)tetrafluoroethane as a white solid having a melting point of 154-157° C. This corresponds to a yield of 90% of theory.
MS (EI) 458 (3%)[M + ], 229 (100)[Cl—C 6 H 3 (—CF 3 )—CF 2 + ]
Example 10
Etherification with Benzyl Alcohol
216 g of benzyl alcohol together with 1 liter of N,N-dimethylacetamide were placed in a reaction vessel and cooled to 0° C. 336 g of potassium hydroxide powder was added a little at a time at 0-2° C. over a period of 25 minutes. A solution of 290 g of 1,2-di(4-fluorophenyl)tetrafluoroethane in 500 ml of N,N-dimethylacetamide was subsequently added dropwise at 2-14° C. over a period of 45 minutes. The mixture was stirred for 30 minutes at 14-25° C., then for 16 hours at 84-92° C. The resulting suspension was poured into 2 liters of water, the solid was filtered off with suction, washed with water, and dried at 60° C.
This gave 445 g of 1,2-di(4-benzyloxyphenyl)tetrafluoroethane as a white solid having a purity of 93.4% (HPLC-% by area) and a melting point of 206-208° C. This corresponds to a yield of 95% of theory.
1 H-NMR (d 6 -DMSO, 400 MHz): [δ in ppm] 7.62-7.36 (18H, m); 5.33 (4H, s)
19 F-NMR (d 6 -DMSO, 376 MHz): [δ in ppm]−109 (4F, s)
MS (Cl) 489 (100%) [M+Na + ], 447 (83) [M + −F]
When 2 kg of 1,2-di(4-fluorophenyl)tetrafluoroethane were used as starting material, the corresponding procedure gave 3.13 kg of 1,2-di(4-benzyloxyphenyl)tetrafluoroethane as a white solid having a melting point of 206-208° C. This corresponds to a yield of 97% of theory.
Example 11
Etherification with Benzyl Alcohol
42.1 g of KOH (85-90% pure, pellets) together with N-methylpyrrolidone (300 ml) were placed in a reaction vessel under a nitrogen atmosphere at room temperature. After 100 ml of N-methylpyrrolidone had been added, the stirrer was switched on. After everything had been added, the mixture was heated to 100° C. 100 g of 1,2-di(3,4-dichlorophenyl)tetrafluoroethane were subsequently added dropwise over a period of 30 minutes, and 26.4 ml of benzyl alcohol were then added dropwise of a period of 10 minutes. The mixture was stirred at 100° C. for another 20 hours, and 180 ml of solvent were then distilled off via a 10 cm Vigreux column. The residue that remained was slurried in 500 ml of water and then filtered off with suction. The solid was washed with water (3 times using 500 ml each time). The residue was dried at 70° C. in a convection oven.
This gave 113.5 g of 1,2-di(3-chloro-4-benzyloxyphenyl)tetrafluoroethane as a white solid. This corresponds to a yield of 83% of theory.
1 H-NMR (d 6 -DMSO, 400 MHz): [δ in ppm] 7.85-7.36 (16H, m) 5.31 (4H, s)
19 F-NMR (d 6 -DMSO, 376 MHz): [δ in ppm]−109 (4F, s)
MS (EI): 534 (2%) [M + ], 91 (100) [C 6 H 5 CH 2 + ]
Example 12
Etherification with Benzyl Alcohol
36.0 g of KOH (85-90% pure, pellets) together with N-methylpyrrolidone (200 ml) were placed in a reaction vessel under a nitrogen atmosphere at room temperature. After 100 ml of N-methylpyrrolidone had been added, the stirrer was switched on. After everything had been added, the mixture was heated to 100° C. 100 g of 1,2-di(3-trifluoromethyl-4-chlorophenyl)tetrafluoroethane in N-methylpyrrolidone (50 ml) and then 22.5 ml of benzyl alcohol were subsequently added dropwise. The mixture was stirred at 100° C. for another 42 hours, and 90 ml of solvent were then distilled off via a 10 cm Vigreux column. The residue that remained was slurried with water and then filtered off with suction. The solid was washed with water (3×200 ml). The residue was dried at 70° C. in a convection oven.
This gave 49 g of 1,2-di(3-trifluoromethyl-4-benzyloxyphenyl)tetrafluoroethane as a white solid. This corresponds to a yield of 53% of theory.
1 H-NMR (d 6 -DMSO, 400 MHz): [δ in ppm] 7.83 (2H, d, J 9.0 Hz); 7.56-7.36 (16H, m); 5.38 (4H, s)
19 F-NMR (d 6 -DMSO, 376 MHz): [δ in ppm]−61 (6F, s), −109 (4F, s)
MS (EI) (1%) [M + ], 91 (100) [C 6 H 5 CH 2 + ]
Example 13
Ether Cleavage by Hydrogenation
2866 g of 1,2-di(4-benzyloxyphenyl)tetrafluoroethane together with 28 liters of ethanol were placed in a hydrogenation vessel and admixed with 280 g of 5% palladium on activated carbon. The vessel was subsequently pressurized with 2-4 bar of hydrogen for 15 hours at 25-30° C. and then depressurized. The mixture was filtered with suction and the filtrate was evaporated.
This gave 1718 g of 1,2-di(4-hydroxyphenyl)tetrafluoroethane as a white solid having a purity of 98.4% (HPLC-% by area) and a melting point of 224-225° C. This corresponds to a yield of 98% of theory.
1 H-NMR (d 6 -DMSO, 400 MHz): [δ in ppm] 7.18 (4H, d, J 8.6); 6.85 (4H, d, J 8.6)
19 F-NMR (d 6 -DMSO, 376 MHz): [δ in ppm]−109 (4F, s)
MS (EI) 286 (14%) [M + ], 143 (100) [HO—C 6 H 4 —CF 2 + ]
Example 14
Ether Cleavage by Hydrogenation
113 g of 1,2-di(3-chloro-4-benzyloxyphenyl)tetrafluoroethane together with 500 ml of ethanol were placed in a hydrogenation vessel and admixed with 1 g of 5% palladium on activated carbon. The vessel was subsequently pressurized with 2-4 bar of hydrogen for 30 hours at 25-30° C. and then depressurized. The mixture was filtered hot and the filtrate was evaporated.
This gave 45 g of 1,2-di(3-chloro-4-hydroxyphenyl)tetrafluoroethane as a white solid. This corresponds to a yield of 60% of theory.
19 F-NMR (d 6 -DMSO, 376 MHz): [δ in ppm] −110 (4F, s)
MS (Cl) 355 (100%) [M+H + ]
Example 15
Ether Cleavage by Hydrogenation
100 g of 1,2-di(3-trifluoromethyl-4-benzyloxyphenyl)tetrafluoroethane together with 500 ml of ethanol were placed in a hydrogenation vessel and admixed with 1 g of 5% palladium on activated carbon. The vessel was subsequently pressurized with 2-4 bar of hydrogen for 10 hours at 25-30° C. and then depressurized. The mixture was filtered and the filtrate was evaporated.
This gave 29 g of 1,2-di(3-trifluoromethyl-4-hydroxyphenyl)tetrafluoroethane as a white solid having a purity of 98.9% (GC-% by area). This corresponds to a yield of 85% of theory.
1 H-NMR (d 6 -DMSO, 400 MHz): [δ in ppm] 11.45 (2H, s); 7.58 (2H, d, J 8.6 Hz); 7.38 (2H, s); 7.20 (2H, d, J 8.6 Hz)
19 F-NMR (d 6 -DMSO, 376 MHz): [δ in ppm]−61 (6F, s), −110 (4F, s)
MS (EI) 422 (12%) [M + ], 211 (100) [HO—C 6 H 3 (—CF 3 )—CF 2 + ]
|
This invention relates to 1,2-di(4-hydroxyaryl)tetrafluoroethanes of the general formula (I)
wherein
R are each, independently of one another, hydrogen, F, Cl, Br, I, CN, COOR 2 , C 1 -C 4 -alkyl, C 1 -C 4 -alkoxy, C 1 -C 4 -alkylthio, C 1 -C 4 -perfluoroalkyl, C 1 -C 4 -perfluoroalkoxy, C 1 -C 4 -perfluoroalkylthio, C 1 -C 4 -polyfluoroalkyl, C 1 -C 4 -polyfluoroalkoxy, or C 1 -C 4 -polyfluoroalkylthio, R 2 is C 1 -C 4 -alkyl, and n is an integer from 0 to 4.
This invention further relates to the preparation of such compounds as well as to precursors and intermediates that can be used in their preparation.
| 2
|
BACKGROUND OF THE INVENTION
The invention pertains to a textile industry in general. More particularly, the invention relates to a reed with parallel reed dents running parallel to each other and spaced by a distance defined by a spring.
Reeds of the type under consideration are known in the art. The ends of the reed dents are usually glued in connecting hulls or capsules. In mounting of the reed dents in the hulls it is important that the reed dents should be held in exact parallel position and should be maintained in the precise parallel position at the opposite sides of the weaver's reed. This problem, however has not been completely solved in conventional constructions of the type under discussion. For example, in the hull structure disclosed in DE-OS No. 21 27 209 published Feb. 8, 1973 and including two halves clamped on one another there is possibility that the parallel position of two reed dents will be disturbed during the compressing of two hull halves together. Also, the desired twisting property of the hull during the pivoting connection of the two hull halves will be effected. The division of the hull into two separate but not contacting halves of a conventional type does not improve the construction of the hull because in such a construction the twisting property of a U-shaped channel in the hull is not obtained, and since the hulls often are located in the area of the ends of the reed dents glue or adhesive material connecting the hull portions to each other can flow out from the hull portions.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved weaver's reed capsule.
It is another object of the invention to provide a connecting hull or a capsule for a reed, in which the parallel position of the reed dents and that of the outer sides of the hull are ensured.
Still another object of the invention is to provide such a construction of the hull, in which an adhesive material does not flow out from the connected parts.
These and other objects of the invention are attained by a reed capsule with parallel reed dents spaced from each other at a distance defined by a spring, comprising a lower and an upper hulls in which the ends of the reed dents are glued in, at least the lower hull including two longitudinal halves connected to each other so as to form a channel receiving the ends of the reed dents, each of said halves including a portion, the portion of one of said halves overlapping the portion of another of said halves and being sealingly connected thereto.
According to further features of the invention each of the halves may have an L-shape cross-section, a horizontally extending projection of one half overlapping a horizontally extending projection of another half of the hull.
One portion of the hull halves may include an outwardly extending projection and the portion of another of the halves may include two outwardly extending projections spaced from each other to form a recess therebetween, said outwardly extending projection of the one portion engaging in said recess.
In accordance with further features of the invention each of the portions may be formed with a groove-like recess, the hull further including a connecting element extending between said two halves and engaged in the groove-like recesses of said portions.
The connecting element may be made out from an elastic material.
According to still further features of the invention the connecting element may be provided with two opposite enlarged end portions, the aforementioned recesses being formed with respective enlarged regions, said end portions being engaged in said enlarged regions when the connecting element is inserted into said recesses.
Due to the fact that the connecting hull or capsule is divided into two portions sealingly connected to each other in the bottom area of the hull the maintaining of the parallel position of the outer surfaces of the hull after the hull halves have been assembled to each other can be easily obtained without exercising a strong pressure. It is thereby warranted that the parallel position of the reed dents during the assembling of the hull is not changed.
Due to the overlapping position of two projections formed on the hull halves the flowing of a glue utilized for connecting the ends of the reed dents to the hull out of the connection is totally prevented. The connection of reed dents to the hull according to the invention is therefore very rigid and stable.
If a connecting bar of an elastic material is utilized as mentioned above a very reliable locking or arresting correction will be obtained.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view through a connecting hull of a weaver's reed according to a first embodiment of the invention;
FIGS. 2 and 2a are sectional views through a connecting hull in accordance with another embodiment of the invention;
FIGS. 3 and 3a are sectional views through a connecting hull according to a still further embodiment of the invention;
FIGS. 4 and 4a illustrate sectional views through a hull of still another modification of the invention; and
FIGS. 5 and 5a show sectional views through a hull in accordance with yet another embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the sectional views shown in FIGS. 1-5 only a lower binding hull or capsule with one ends of reed dents is illustrated and wherein a known per se screw spring is provided to define a spaced relationship between the reed dents. In all the figures the respective illustrated end of the reed dent is designated by a reference character 10 and the spring is denoted by a reference numeral 11. An insert by means of which spring 11 is coupled to the end of the reed dent is denoted by numeral 12.
Referring now to FIG. 1, it will be seen that this figure shows a cross-section through a binding hull or capsule 13 including uneven halves 13a and 13b each having an L-shaped cross-section and connected so that their outwardly projecting horizontal legs or portions 13c and 13d sealingly overlap each other in the region of the bottom of the hull 13. Therefore, a fused adhesive usually placed (not illustrated in the drawing) onto the bottom of the hull between the individual reed dents will not flow out from the hull.
FIG. 2 illustrates a connecting hull 14 enclosing the end of the reed dent and including a first hull half 14a and a second hull half 14b. Hull half 14b is formed with a projecting bar 14c in the region of the bottom of the hull, which bar extends into and sealingly engages in a longitudinal groove 14d respectively provided in the lower region of the hull half 14b. The extension of the projecting bar 14c into longitudinal groove 14d corresponds to the thickness (width) of the end of the reed dent 10 so that this end is arrested in the band hull by means of an adhesive poured into the channel between halves 14a and 14b.
FIG. 2a shows a relative position of two hull halves 14a and 14b during the twisting of the reinforced (having a greater width) reed dent 10'. The structure of the both hull halves ensures here also a reliable sealing of the inner space of the hull. In contradistinction to the embodiment of FIG. 1 spring 11 in the embodiment of FIGS. 2 and 2a is covered by means of projections 30 made on the hull halves in a known fashion.
In the embodiment shown in FIGS. 3 and 3a the connecting hull includes two mirror-inverted halves 15a and 15b, each formed with a respective projection 15c or 15d provided in the lower area of the hull. In the assembled position of the hull projections 15a and 15d form respective grooves 15e and 15f into which a flat connection bar 16 extends with its peripheral edge. This connection bar acts as a coupling between two hull halves 15a and 15b, which coupling seals the hull in its bottom area so that no adhesive will flow out through a clearance 17 between the end faces of projections 15c and 15d.
As seen in FIG. 3a the hull can be adjusted to the various thicknesses of the reed dent 10 by utilizing connecting bars of different lengths.
FIGS. 4 and 4a illustrate a further embodiment of the invention, in which grooves 18c and 18d are formed between the respective opposite projections formed in the bottom part of the hull so as to provide two opposite clearances 20 on each side of the connection bar 19. In this structure the hull may be adjusted to the various thicknesses of the reed dent 10 without requiring connection bars 19 of different widths, i.e. the same connection bar 19 can be utilized for the various reed dents. In this construction connection bar 19 acts as a sealing between projections 18c' and 18d' within clearance 20.
FIGS. 5 and 5a show an embodiment, in which the mirror-inverted halves 21a and 21b are provided analogous to those of FIGS. 3, 3a and 4, 4a.
Halves 21 and 21b have lower portions 21c, 21d which are formed with longitudinal grooves 21e, 21f adapted to sealingly receive a connection bar 22. In this embodiment connection bar 22 is formed of an elastic material and is provided with reinforcing beads 22a at the opposite edges thereof. Beads 22 in assembly engage in respective enlarged portions of grooves 21e, 21f so as to form a locking or arresting connection. Reinforcing bead-like portions 22 of connection bar 22 will slide into the grooves 21e, 21f under elastic pressures produced by insertion of the bar 22 into the grooves and then yieldingly slip into the enlarged portions of those grooves. If grooves 21e and 21f are of a greater length as shown in FIG. 5a adjustment of the hull may be made to a greater thickness of the reed dent 10' with the use of the same connection bar 22.
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 weaver's reeds, differing from the types described above.
While the invention has been illustrated and described as embodied in a reed with two parallel reed dents, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
|
In a weaver's reed provided with two parallelly running reed dents spaced from each other by a spring, the ends of the reed dents are glued in connecting hulls. Each hull is formed of two substantially L-shaped halves each provided with an outwardly extended portion. The halves are so connected to each other than the outwardly extended portion of one half overlaps the portion of another half.
| 3
|
[0001] The present invention relates to a dough portion control machine from flour and similar, particularly for pizza-restaurants. bakeries etc., comprising a dough feeding hopper, dough extrusion means and dough weight and/or dimension selective control means.
[0002] Nowadays pizzas, bread portions and similar are requested for a weight up to 1.5 lb. Consequently a plurality of dough portions machines adapted to the production of a plurality of pizzas, bread different portions is offered to the market of pizza-restaurants, bakeries and so on.
[0003] A known machine is conceived to select dough portions from about 0.1 to maximum 0.7 lb. thanks to a simple device, which provides a dough portions weight selection device by means of an outlet cross section funnel adjustement, which is placed down with respect to a screw feeder. A rotating blade is starting down the screw feeder by means of a sensor, where an operator can preventively select different dough portion weights.
[0004] Should dough portions of different weight be required, substantially higher than 0.1-0.7 lb., further more sophisticated, expensive and cumbersome machines are necessary.
[0005] An interesting solution could be offered by the same above mentioned machine, which could offer thanks to a simple device the opportunity to prepare dough portions from 0,1-0.7.lb. to 0.7-1.5 lb. The main advantage of such a solution could be given both by reduction of the space, which should be required in presence of a plurality of different machines and by a substantial cost reduction for more than one equipment.
[0006] Such a problem is solved by the machine according to the invention, which is characterized in that extrusion means are adapted to co-operate with dough cutting means and with extruded dough portion control means, said extrusion means being adapted to produce together with said cutting means and with control means dough portion which could be even substantially heavier than for instance 0.7lb., interchangeability means of said extrusion means with further extrusion means being provided on the same machine structure for dough portion production, which could be even lighter than 0.7lb., for instance within a range 0.1-0.7lb., with the advantage to prepare dough portion comprised within a range of 0.1-1.5lb. and even heavier.
[0007] Said and further characteristics will be apparent from the following description and the alleged drawings, where:
[0008] [0008]FIG. 1 represents FIG. 1 of Italian Patent No. 01253370;
[0009] [0009]FIG. 2 represents a perspective view of machine according to the invention;
[0010] [0010]FIGS. 3 a , 3 b rapresent respectively a front view of machine according to the invention in correspondence of a starting phase, as well as an enlargement of a particular device of the same machine taken in a plant view;
[0011] [0011]FIG. 4 represents a front view of the machine according to the invention in correspondence of a second operation phase of the same machine;
[0012] [0012]FIG. 5 represents a perspective view of a partial interior of the machine according to the invention.
DESCRIPTION
[0013] The machine according to the invention comprises a hopper 1 (FIGS. 2 , 3 , 4 ) for storage and processing of dough, from which single portions are obtained. Said machine comprises also a screw feeder 2 (FIG. 5). This latter represents extrusion means, which are described and represented in detail with 21, 22, 211, 221 (FIG. 1) also in the Italian Patent No. 01253370 issued on Aug. 6, 1995.
[0014] Said screw feeder 2 (FIG. 5) is adapted to operate thanks to an electric motor, which is settled externally with respect to the machine and which is not represented in the dawings.
[0015] A cone-shaped horizontal distributor 3 (FIGS. 3 a , 3 b , 4 ) is represented in correspondence of the end of a cover 4 of the screw feeder 2 , which allows the dough to leave the machine. The single portions of different weight and dimensions are obtained thanks to the pressure exerted by screw feeder 2 into the cover 4 , and thanks to further devices, which will be apparent forwards.
[0016] Distributor 3 is fixed to a vertical wall 5 (FIGS. 3 a , 4 , 5 ), for instance by means of two handwheels 6 . Said handwheels allow a simple disassembly from the machine of distributor 3 , whereby further different distributors 3 can be assembled, as it will be explained forwards.
[0017] Distributor 3 is adapted to produce dough portions having a weight comprised within a range of 0.7-1.5 lb. and even more. Distributor 3 represents means adapted to render the machine compatible with performances of a machine, which could produce dough portions substantially lighter than 0.7 lb.
[0018] Distributor 3 presents a cone-shaped section outlet and is provided with a longitudinal axis substantially inclined on a vertical plane (FIG. 3 b ) with respect to longitudinal development of the machine due to overall dimensions, as it will be apparent forwards:
[0019] The screw feeder 2 , which is inside cover 4 , and distributor 3 represent extrusion means of the machine according to the invention, whereas handwheels 6 represent interchangeability means of distributor 3 with different distributors, which are adapted to produce different weight and dimension dough portions, for instance also lower with respect to dough portions, which are produced by the machine according to the invention.
[0020] A paddle 7 (FIGS. 3 a , 4 ) is fixed by means of a stud 8 inside a notch which is obtained on a cylindrical block 9 . Paddle 7 (FIG. 3 b ) is adapted to slide in a way known per se forwards or backwards with respect to longitudinal development of the machine, together with block 9 , thanks a handle 10 (FIG. 2), so that an operator is allowed to select the amount of dough, which should form a portion weight, as it will be explained forwards.
[0021] Handle 10 represents weight and/or dimension dough portions selective control means. In addition paddle 7 is adapted to turn on (in a forward direction) just a bit due to pressure of dough, which leaves distributor 3 , whereby it can act on a microswitch (not represented in the drawings), which is adapted to make an electric motor 11 (FIGS. 3 a , 4 ) start. The motor 11 should transmit by means of a reduction gear 12 a rotation of 360° in the direction of arrow A to a shaft 13 . A cam 14 is fixed on said shaft 13 .
[0022] Rotation of cam 14 is transmitted by shaft 13 to a blade 16 (FIG. 3 a ), which represents dough cutting means of the machine according to the invention. FIG. 3 a shows rest position of blade 16 , which is adapted to rotate clockwise in order to cut a dough worm, which leaves distributor 3 . FIG. 4 shows blade 16 after cutting dough warm.
[0023] A further microswitch arranged on shaft 13 and not represented in the drawings, should stop in a way known per se shaft 13 rotation after just one revolution.
[0024] A square 17 is adapted to co-operate with cam 14 , which is represented in FIG. 3 a in a rest device position. Square 17 is adapted to rotate on a block 18 , which is fixed to wall 5 of the machine according to the invention and adheres to cam 14 profile by means of a spring 24 . As soon as motor 11 starts, a rotation is transmitted to shaft 13 , cam 14 makes square 17 rotate in the direction of arrow B and causes in a way known per se rotation of a shaft 26 , on which a support 27 is fixed.
[0025] Support 27 represents support means of dough worm, which leaves screw feeder 2 until blade 16 is cutting said worm, avoiding in such a way that dough portion falls down. Operator should have previously selected dough dimensions after fixing axial position of block 9 thanks to handle 10 (FIG. 2), as it was explained before.
[0026] Cam 14 , square 17 , shaft 26 and support 27 represent extruded dough portion control means of the machine according to the invention.
[0027] The machine operates according the following way.
[0028] After dough is leaving screw feeder 2 , it goes along distributor 3 and encounters paddle 7 . This latter assumes an axial position (in a longitudinal direction of the machine) together with block 9 , which corresponds to choice of pre-selected dough portion amount. Such a pre-selection is obtained by adjusting handle 10 (FIG. 2). This latter is provided with notches, which allow the operator to select a precise dough portion amount.
[0029] Paddle 7 is turning on just a bit as soon as dough worm encounters it. Such a rotation make a microswitch activate, whereby motor 11 is starting and makes shaft 13 and cam 14 rotate 360°. Blade 16 is consequently rotating and a pre-selected dough portion is cutted. Such a portion could fall down into a container not represented in the drawings, should support 27 didn't collect it and keep it close to distributor 3 . As soon as shaft 13 is rotated 360° a further microswitch stops shaft 13 .
[0030] The dough worm, which leaves distributor 3 , could now fall down or could bend before blade 16 cuts it. As explained, in order to avoid such a drawback, support 27 collects dough and keeps it until blade 16 cuts the pre-select dough amount. All this thanks to square 17 rotation in B direction, which happens as soon as blade 16 has cutted the pre-selected dough portion. After such an operation support 27 rotates clockwise (FIGS. 3 a , 4 ), releases cutted dough portion and makes said portion fall down into a container.
[0031] It is to be point out that structure of the machine according to the invention is substantially not so different from the machine claimed in the cited Italian Patent. The main difference between two machines is given both by distributor 3 , which is now in the condition to supply dough portions heavier than 0.7 lb. and all devices, which were explained up to now: shaft 13 , cam 14 , square 17 , support 27 as well as all microswitch not represented in the drawings but functionally explained.
[0032] The different dimensions of distributor 3 have to be coupled with its longitudinal axis, which should be now substantially rightwards inclined in FIGS. 3 a , 3 b , 4 . Reasons of such an inclination are depending on the fact that, in such a way blade 16 , which is provided with the same blade dimensions claimed in the already cited Italian Patent, could cut the entire dough amount, which leaves the screw feeder 2 . Otherwise, i.e. if the distributor 3 was conceived provided with the substantially right longitudinal axis, cutting capacity of blade 16 should have been increased, and consequently structure of the new machine with respect of machine claimed in the cited patent should have been different, particularly increased.
[0033] Therefore distributor 3 represents as well as its inclined longitudinal axis, means adapted to get the machine according to the invention compatible with a machine adapted to produce dough portions substantially lower than 0.7 lb.
[0034] When the machine according to the invention should be adapted to a production of dough portions lighter than a weight comprised within a range of about 0.7-1.5 lb. and more, handwheels 5 should be unscrewed, distributor 3 should be disassembled from machine frame and changed with a different distributor, for instance with distributor, which is described with n.3 in FIG. 1 of already cited Italian patent. Such a distributor allows production of dough portions, which are substantially lighter and comprised within a range of about 0.1-0.7 lb.
[0035] Therefore the main advantage, which is offered by the machine according to the invention, is represented by the fact that pizza-restaurants are not required to be equipped with more than one machine for production of dough portions comprised within a range of 0.1-1.5 lb. No further investments are necessary besides cost of just one machine.
|
A dough portion control machine for flour and similar materials comprises a dough feeding hopper, a dough extrusion apparatus including first and second a interchangeable dough distributors, a dough weight and dimension apparatus, a dough cutting apparatus, and a extrusion portion control apparatus. The first dough distributor is adapted to cooperate with the dough cutting apparatus and the extrusion dough portion control apparatus to produce dough portions in the range of 0.1-0.7 lb. and the second dough distributor, when interchanged with the first dough distributor, is adapted to cooperate with the dough cutting apparatus and the extrusion dough portion control apparatus to produce dough portions in range of 0.7-1.5 lb. and even heavier.
| 0
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/607,300, filed Mar. 6, 2012, and entitled “Portable Wind Break Device,” which is hereby incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] The invention relates to a portable wind break device with improved portability, assembly and stability.
[0004] Portable wind break devices are useful to block weather elements such as wind, sun and rain, and to provide privacy or concealment. Therefore, portable wind break devices have useful applications in public or private areas and in areas of varying weather patterns. Portable wind break devices are typically made of a fabric supported in a generally upright position by poles that are attached to the fabric by methods such as sewing or heating. The poles are generally of sufficient length to have a protruding end that can be pushed into the ground to stand the wind break device upright. This configuration, however, often limits use of portable wind break devices to areas with ground soft enough to receive the protruding ends of the poles, yet firm enough to form a secure connection with the protruding ends. Additionally, portable wind break devices are not properly securable in an upright position while being used on a man-made surface, such as a deck, a patio or pavement. Further, conventional portable wind break devices suffer from a limited use of practical applications, thereby limiting the benefit and user of the product to a position of having to sit on or near the ground.
[0005] Further, conventional wind break devices typically include some form of folding, portable sun and/or windscreen which can be erected or stowed. Such devices usually incorporate a collapsible metal rod frame over which a canvas or plastic material cover can be attached. These devices are, however, relatively cumbersome and not particularly well adapted for single handed erection nor are they very stable to withstand the rigors of high winds.
[0006] There is a need, therefore, for a portable wind break device which can be quickly and easily erected by one person without the use of tools, will be effective and stable when mounted on a surface for use in strong winds, and that is adaptable in shape and size, offering flexibility for various applications and settings.
SUMMARY OF THE INVENTION
[0007] The present invention relates to a portable wind break device for blocking wind. The portable wind break device includes a plurality of connecting poles that each include a first channel, a second channel and a receiving aperture. The portable wind break device further comprises a panel which includes a first bead and a second bead that extend along an edge portion of the panel. The first bead and the second bead are configured to be received by the first channel of a first connecting pole and the second channel of a second connecting pole, respectively. Further, the portable wind break device includes a reinforcing support which has coupling elements that engage the plurality of connecting poles and the panel, thereby providing opposing pressure to the portable wind break device.
[0008] In another embodiment, the portable wind break device includes a first connecting pole and a second connecting pole where each of the first and second connecting poles includes a first channel, a second channel and a receiving aperture. The wind break device further includes a panel which includes a first bead and a second bead. The first bead extends along and is coupled to a first vertical edge portion of the panel. The second bead extends along and is coupled to a second vertical edge portion. The first bead is configured to be received by the first channel of the first connecting pole, and the second bead is configured to be received by the second channel of the second connecting pole. The wind break device also includes a reinforcing support which includes a first end and a second end. The first end includes a first coupling element, and the second end includes a second coupling element, such that the first coupling element engages the first connecting pole and the second coupling element engages the second connecting pole, thereby providing an opposing pressure between the first connecting pole and the second connecting pole.
[0009] In another embodiment, a method for assembling a portable wind break device is disclosed. The method includes inserting a first connecting pole and a second connecting pole into a first staking pole and a second staking pole, each of the first connecting pole and the second connecting pole including a first channel, a second channel and a receiving aperture. The method further includes sliding a first bead into the first channel of the first connecting pole and sliding a second bead into the second channel of the second connecting pole, respectively, the first bead extending along and is coupled to a first vertical edge portion of a panel, and the second bead extending along and is coupled to a second vertical edge portion of the panel. The first connecting pole and the second connecting pole are joined with a first end and a second end of a reinforcing support. The first end includes a first coupling element and the second end includes a second coupling element. The first connecting pole is then engaged with the first coupling element and the second connecting pole is engaged with the second coupling element, such that the reinforcing support provides an opposing pressure between the first connecting pole and the second connecting pole.
[0010] These and other features, aspects, and advantages of the present invention will become better understood upon consideration of the following detailed description, drawings, and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of a portable wind break device according to one embodiment of the present invention.
[0012] FIG. 2 is an exploded perspective view of a connecting pole and reinforcing supports of FIG. 1 .
[0013] FIG. 3 is a perspective view of the connecting pole coupled to reinforcing supports in the device of FIG. 1 .
[0014] FIG. 4 is a top cross-sectional view of the connecting pole coupled to a staking pole and panels.
[0015] FIG. 5 is an exploded side perspective view of a portion of the portable wind break device of FIG. 1 .
[0016] FIG. 6A is a perspective view of a mounting support for the portable wind break device of FIG. 1 .
[0017] FIG. 6B is a perspective view of an alternative mounting support for the portable wind break device of FIG. 1 .
[0018] FIG. 7A is a side perspective view of the connecting pole coupled to the panels.
[0019] FIG. 7B is a detail perspective view of a side edge portion of a panel.
[0020] FIG. 8 is a top plan view of the portable wind break device of FIG. 1 .
[0021] FIG. 9 a side perspective view of a portion of the portable wind break device of FIG. 1 .
[0022] FIG. 10 is an enlarged perspective view of the connecting pole coupled to the reinforcing support.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
[0024] The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of embodiments of the invention.
[0025] FIGS. 1 and 8 illustrates an example portable wind break device 10 in a fully assembled state. The wind break device is shown in an arching pattern, although other arrangements are possible, including generally straight, curved, and zig-zag, for example. The portable wind break device 10 includes a first staking pole 12 and a second staking pole 13 which axially accept a plurality of connecting poles 14 along an axis 16 . The plurality of connecting poles 14 include a first channel 18 and a second channel 20 which axially accept a first bead 22 and a second bead 24 , respectively, of a panel 26 . The panels 26 can be reinforced by reinforcing supports 28 which include a coupling element 30 attached to end portions 32 of the reinforcing supports 28 , shown in FIGS. 2 and 3 . In some embodiments, the coupling element 30 is a coupling ring. The coupling elements 30 are axially accepted by the plurality of connecting poles 14 which creates an opposing pressure between two connecting poles to additionally support and reinforce the plurality of connecting poles 14 .
[0026] Turning now to FIGS. 4 and 5 , the first and second staking poles 12 , 13 are shown. The first and second staking poles 12 , 13 are generally rigid and include a first end 34 , a second end 36 and a base plate 38 . The base plate 38 can include a slot 35 , which allows a plurality of stakes to slide together for smaller packaging without reducing the strength or use of the staking poles. It is to be appreciated that the base plate 38 can take any convenient shape and does not have to be round and does not have to include the slot 35 . The first end 34 of the first and second staking poles 12 , 13 can be cylindrical in shape and have an outside diameter (not shown) smaller than an inside diameter (not shown) of a receiving aperture 40 of the plurality of connecting poles 14 such that the plurality of connecting poles 14 can slide over the first ends 34 of the first and second staking poles 12 , 13 as shown in FIG. 4 . The second end 26 of the first and second staking poles 12 , 13 can have a conical shape with a pointed end 42 , allowing the first and second staking poles 12 , 13 to be inserted into a relatively soft surface (not shown). The base plate 38 is coupled (e.g., welded) perpendicularly between the first end 34 and second end 36 of the staking pole 12 and centered along the axis 16 , shown in FIG. 5 . The staking poles 12 are generally constructed of aluminum, steel or any other suitable rigid material to limit the first and second staking poles 12 , 13 from bending, as well as withstand being inserted into the surface (e.g., the ground). Further, the first and second staking poles 12 , 13 can be painted to prevent rusting.
[0027] Alternatively, a mounting support 44 , as shown in FIGS. 6A , and 6 B can be used for securing the portable wind break device 10 to a hard surface, such as a deck, pavement, blacktop, ice, stone or any surface where the first and second staking poles 12 , 13 may not be effective. Similar to the first and second staking poles 12 , 13 , the mounting supports 44 accept the plurality of connecting poles 14 , thereby holding them firmly in place, as well as vertically stiff. The mounting support 44 includes a bottom plate 46 which can have a generally round or square shape and securing holes 48 positioned on corner sections 50 of the bottom plate 46 . Bolts, screws, pins, nails or any suitable fastener can be inserted into the securing holes 48 to secure the mounting support 44 to the hard surface. The mounting support 44 of FIG. 6A further includes a mounting post 51 that can be cylindrical in shape and can have an outside diameter (not shown) smaller than an inside diameter (not shown) of the receiving aperture 40 of the plurality of connecting poles 14 such that the plurality of connecting poles 14 can slide over the mounting post 51 of the mounting support 44 . The alternative mounting support 44 of FIG. 6B further includes a hollow mounting post 52 perpendicularly coupled (e.g., welded) to the bottom plate 46 along the axis 16 . The hollow mounting post 52 can have a cylindrical shape with a receiving aperture 54 . The receiving aperture 54 is designed to axially receive the plurality of connecting poles 14 , such that the mounting support 44 provides rigidity and support for the plurality of connecting poles 14 . The mounting supports 44 are generally constructed of aluminum, steel or any other suitable rigid material to limit the mounting support 44 from bending. Further, the mounting supports 44 can be painted to prevent rusting.
[0028] Turning now to FIGS. 2 and 3 , the connecting poles 14 include a first channel 18 and a second channel 20 which extend parallel to one another the entire length of the plurality of connecting poles 14 . The first channel 18 and the second channel 20 are designed to mate with the first bead 22 and the second bead 24 of the panel 26 , which will be described in further detail below, such that the first bead 22 and the second bead 24 axially slide into the first channel 18 of a first connecting pole 14 and the second channel 20 of a second connecting pole 14 , thereby coupling the panel 26 between the plurality of connecting poles 14 and restricting the first bead 22 from being removed laterally from the first channel 18 , as well as restricting the second bead 24 from being removed laterally from the second channel 20 . The plurality of connecting poles 14 further include an end portion 56 , best shown in FIG. 6A , with a receiving aperture 40 that is designed to be inserted into the mounting support 44 or over the first or second staking pole 12 , 13 . The plurality of connecting poles 14 also include an outer surface 58 in which the coupling elements 30 of the reinforcing support 28 can slide over, shown in FIGS. 2 and 3 . The plurality of connecting poles 14 can be constructed of a high-quality, lightweight aluminum or any other suitable material to easily allow for additional panel 26 add-ons.
[0029] Turning now to FIGS. 4 , 7 A and 7 B, the panels 26 are generally square or rectangular in shape and include a first bead 22 and a second bead 24 tightly sewn along a first edge portion 60 and a second edge portion 61 of the panel 26 (see FIG. 7A ). The first bead 22 and the second bead 24 can be cylindrical in shape and can be constructed of plastic or any other suitable material. In an alternative embodiment shown in FIG. 7B , the first bead 22 and the second bead 24 can comprise a plastic bead welt 23 that includes an end portion 25 that the panel can be sewn 27 or otherwise securely coupled to. The plastic bead welt 23 can help to keep the panel material out of the first channel 18 and second channel 20 . The first bead 22 and the second bead 24 give the first edge portions 60 and the second edge portions 61 rigidity and are dimensioned such that they can be easily slid into and out of the first channel 18 and the second channel 20 of the connecting pole 14 , thus making additions or subtractions of panel sections convenient and without the need for tools. As a result of the cylindrical shape of both the beads 22 , 24 and the channels 18 , 20 , there are limitless angles 62 , shown in FIGS. 8 and 9 , at which each panel 26 can be attached to the plurality of connecting poles 14 . Additionally, the portable wind break device 10 can be easily made larger by adding panel 26 sections, since the plurality of connecting poles 14 at the end, shown in FIG. 9 , may have a first channel 18 or a second channel 20 that is vacant and able to accept a new panel 26 section.
[0030] As shown in FIG. 9 , the panels 26 may be constructed of a vinyl fabric, or similar fabric material that is substantially impervious to wind. Toward a top portion 64 of the panel 26 , there may be a viewing window 66 integrated into the panel 26 , which allows a small amount of air through, thus allowing the side loads of variable wind speeds to be higher, being a small “relief” toward the top portion 64 of the panel 26 . The primary purpose of the viewing window 66 is for sustaining a high wind generated side load on the panel 26 , and the portable wind break device 10 overall. Additionally, since the embodiment can be taller than the average user's line of site, while standing, the viewing window 66 can be advantageous to the end user
[0031] Turning now to FIGS. 2 , 3 and 10 , the reinforcing support 28 includes coupling elements 30 attached (e.g., welded) to the end portions 32 of the reinforcing support 28 . The reinforcing support 28 can be constructed of aluminum extrusion or any other suitable material. The coupling elements 30 can be slid over the outer surfaces 58 of the plurality of connecting poles 14 , such that the reinforcing support is aligned generally parallel to the top portion 64 of the panel 26 . Therefore, the reinforcing support 28 creates tension on the panels 26 , through opposing forces between two connecting poles 14 , and reinforces each panel 26 as taught, and unites each panel 26 section together as part of the whole portable wind break device 10 . In some embodiments, the panel 26 has a top edge portion 65 which has a first length 68 and the reinforcing support 28 has second length 70 , such that the second length is larger than the first length, as shown in FIG. 5 , thereby providing an opposing pressure between a first connecting pole 72 and a second connecting pole 74 . The coupling elements 30 on the end portions 32 of the reinforcing supports 28 slide over the plurality of connecting poles 14 , thus completing the attachment of the reinforcing supports 28 to the plurality of connecting poles 14 . The circular shape of the coupling elements 30 , fitting over the plurality of connecting poles 14 , allows for any angle 62 , shown in FIG. 8 , to be achieved, thus allowing the portable wind break device 10 to be adaptable to a multitude of shapes and applications.
[0032] As best shown in FIG. 5 , the portable wind break device 10 is first assembled by placing a first staking pole 12 or the mounting support 44 on the desired surface. The first connecting pole 72 is then coupled to either the first staking pole 12 or the mounting support 44 . The first bead 22 of the panel 26 is slid into the first channel 18 of the first connecting pole 72 and extends along the first edge portion 61 of the panel 26 . The second bead 24 of a separate panel 26 is slid into the second channel 20 of the first connecting pole 72 along the second edge portion 61 of the panel 26 , shown in FIG. 7A . An additional staking pole 12 or mounting support 44 and a second connecting pole 74 are then placed on the desired surface and the second bead 24 of the panel 26 is slid into the second channel 20 of the second connecting pole 74 . The coupling elements 30 of the reinforcing support 28 are then placed over the outer surfaces 58 of the first and second connecting poles 72 , 74 , as shown in FIGS. 2 and 3 . Depending on the quantity of connecting poles 14 set up, additional panels 26 can be added to the portable wind break device 10 .
[0033] As described above, the portable wind break device 10 provides several advantages over conventional wind break devices. The present portable wind break device 10 permits easy installation and is adaptable to many applications from sporting events to fishing. For any reason in which wind and/or privacy protection may be desired, the portable wind break device 10 allows people to benefit from it even while standing. Additionally, the disclosed invention permits ease in lightweight portability and adaptability for a multitude of surfaces, as well as ease in assembly and disassembly since no tools are required.
[0034] Although a preferred embodiment of the present invention has been illustrated in the accompanying drawings and described in the foregoing Detailed Description, 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 spirit of the invention as set forth and defined by the following claims.
|
Embodiments of the invention provide a portable wind break device which incorporates lightweight staking devices or mounting supports, poles that allow attachment of flexible panels, such as fabric panels, and reinforcing supports which reinforce each panel section, making a modular unit as a whole. The portable wind break device permits ease of portability, set up, take down, and provides wind protection and privacy for people, animals, or anything that would benefit from protection from the wind or privacy. Additionally, the portable wind break device permits easy cleaning, and assembly without tools.
| 4
|
BACKGROUND OF THE INVENTION AND RELATED ART STATEMENT
The present invention relates to a metal-laminate type gasket, such as a cylinder head gasket installed between two members for sealing, such as a cylinder head and a cylinder block and the like. More specifically, the metal-laminate type gasket is formed of more than three metal plates, wherein two of the metal plates are connected together.
In a state that the cylinder head gasket is sandwiched between the cylinder head and the cylinder block (cylinder body) of an engine for an automobile, the cylinder head gasket is tightened by head bolts to seal fluids, such as fuel gas, oil, cooling water and the like.
In a metal-laminate type gasket laminating a plurality of metal plates of the cylinder head gasket, as a method for connecting two plates at a local connecting portion, there is proposed a method in which a claw portion formed in a metal constituting plate is inserted into a fixation hole in the other metal constituting plate to thereby engage the claw portion to a periphery of the fixation holes.
One of the methods, a steel laminate gasket is provided, which is formed of a metal plate provided with hems or flanges constituting hole sealing portions around a plurality of openings constituting combustion chamber holes, and a metal plate provided with notch portions between the openings adjacent to each other by providing to partially overlap the plurality of openings constituting the combustion chamber hole. In the steel laminate gasket, notch holes (fixation holes) are formed between the openings adjacent to each other in the metal plate having no notch portion, and the metal plate with notch portions includes projection portions (claw portions) facing each other. The projection portion (claw portion) is inserted into the notch hole to be engaged (for example, Japanese Utility Model Publication No. 05-59050).
In order to connect two plates with a simple structure and furthermore to facilitate the connecting operation, the metal-laminate type gasket laminating two metal plates includes, at a proper position of the inner surface of a metal-laminate type gasket, includes a tongue piece (claw portion) in one of the two plates by cutting a part of the plate, and a fixation hole for inserting the tongue piece in the other plate. The tongue piece in the one of the two plates is inserted through the fixation hole in the other plate to thereby project toward the other side. Thus, the tongue piece is engaged to the periphery of the fixation hole so that the two laminated plates are fixed each other (for example, Japanese Utility Model Publication No. 06-20955).
However, when the connecting method described above is employed, a thickness of the local connecting portion is increased from the periphery portion with the amount of the tongue piece engaging the periphery of the fixation hole.
Also, recently, in a metal-laminate type gasket laminating a plurality of metal plates, the two plates are connected at a local connecting portion by laser or spot welding. Even though this method is employed, a thickness of the local connecting portion is made greater than that of the periphery portion.
In a state that the thickness of the local connecting portion is increased, when a connecting force is applied between the two members located both sides of the metal-laminate type gasket, a significant high surface pressure is locally generated at the portion where the thickness is locally increased.
Consequently, it can be considered that a third metal plate covers the connecting portion of the two metal plates to thereby disperse the surface pressure. However, when a strong connecting force is applied between engine members, the portion where the thickness is increased abuts against the third metal plate to thereby locally generate a significant high surface pressure at the portion.
Therefore, there has been a problem that the position of the local connecting portion is required to be limited to a portion where sealing property is not affected by the high surface pressure generated, i.e. both ends of the gasket where it is unrelated to sealing or a water jacket portion or the like.
The present invention has been made to solve the above problems, and an object of the present invention is to provide a metal-laminate type gasket formed of more than three metal plates, wherein two of the metal plates, i.e. a first and a second metal plates, are connected at a local connecting portion. In the metal-laminate type gasket, an increase of local surface pressure can be prevented from generating at the connecting portion.
SUMMARY OF THE INVENTION
In order to achieve the above objects, a metal-laminate type gasket according to the present invention is formed of more than three metal plates to connect two of the metal plates, i.e. a first and a second metal plates at a local connecting portion. The metal-laminate type gasket is provided with an opening located at a position facing the connecting portion in a third metal plate covering the connecting portion.
When a strong connecting force is applied between engine members, the local connecting portion having a thickness increased by the connecting operation, does not abut against the third metal plate by the opening. Thus, a high surface pressure can be prevented from generating locally at the connecting portion. Also, the connecting portion can be confirmed from the opening so that an inspection of the connecting portion becomes easy.
In addition, when the metal-laminate type gasket locally connects the first and second metal plates with a structure that a claw portion provided in the first metal plate is engaged to a periphery portion of a fixation hole opened in the second metal plate or an end portion of the second metal plate, the two plates are connected with a simple structure and furthermore the connecting operation can be facilitated.
When the structure of the metal-laminate type gasket described above is applied to a cylinder head gasket, an effect described above can be greatly obtained. Especially, when the structure of the metal-laminate type gasket is applied to a cylinder head gasket having a bore sealing plate with a structure that the first or the second metal plate is a sealing plate for sealing more than one hole among a hole for cylinder bore, a water hole, and oil hole, the connecting portion can be provided near a bead for sealing or the like. Accordingly, the connecting portion is not required to be located away from the bead. Thus, the bore sealing plate can be formed with a small size required for sealing.
Therefore, in the metal-laminate type gasket with the structure described above, a layout structure, such as locations of various holes and the connecting portion of the gasket and the like, can be facilitated.
According to the metal-laminate type gasket of the present invention, the metal-laminate type gasket is formed of more than three metal plates and two of the metal plates, i.e. the first and the second metal plates, are connected at the local connecting portion. Since the opening is provided at the position facing the connecting portion in the third metal plate covering the connecting portion, the local surface pressure can be prevented from generating at the connecting portion.
Accordingly, the connecting portion can be provided near the bead requiring a sealing property. Thus, the layout structure of various holes and the connecting portion of the gasket and the like, can be facilitated.
Also, when the claw portion provided in the first metal plate is engaged with the periphery portion of the fixation hole opened in the second metal plate or the end portion of the second metal plate, the two metal plates can be connected with the simple structure and furthermore a connecting operation can be facilitated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view showing a cylinder head gasket of an embodiment according to the present invention;
FIG. 2 is a partial plan view showing a lower plate at a portion A in FIG. 1 ;
FIG. 3 is a partial plan view showing a bore sealing plate at the portion A in FIG. 1 ;
FIG. 4 is a partial plan view showing an upper plate at the portion A in FIG. 1 ;
FIG. 5 is a partial sectional view showing a connecting portion of the cylinder head gasket;
FIG. 6 is a partial sectional view showing another connecting portion of the cylinder head gasket;
FIG. 7 is a partial sectional view showing a claw portion of the connecting portion of the cylinder head gasket by welding; and
FIG. 8 is a partial sectional view showing the connecting portion by abutting spot welding of the cylinder head gasket.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Next, a metal-laminate type gasket of the embodiments according to the present invention will be explained with an example of a cylinder head gasket for an engine in reference to the accompanying drawings. FIGS. 1 to 8 are schematically explanatory drawings showing a structure for an easy understanding. Thus, the sizes of the holes for cylinder bores, fixation holes, beads, wave beads and the like are different from actual sizes.
The metal-laminate type gasket is the cylinder head gasket sandwiched between two engine members, such as a cylinder head and a cylinder block (cylinder body), for sealing a high temperature and pressure combustion gas of the cylinder bore and liquids, such as cooling water and oil passing through a cooling water path and a lubricating oil path.
As shown in FIGS. 1 to 4 , the cylinder head gasket 1 is formed of three metal plates, i.e. a lower plate (a first metal plate) 10 , a bore sealing plate (sealing plate: a second metal plate) 20 , and an upper plate (a third metal plate) 30 .
The cylinder head gasket 1 is designed for an engine with a plurality of cylinders, and is produced in accordance with a shape of the engine member, such as the cylinder block and the like. As shown in FIG. 1 , the cylinder head gasket 1 comprises holes 2 for cylinder bores (holes for a combustion chamber), water holes 3 for circulation of the cooling water, oil holes 4 for circulation of an engine oil, head bolt holes 5 for tightening head bolts, and the like. Also, sealing means, such as full beads 21 and 31 , are provided around the holes 2 for cylinder bores.
The lower plate 10 is a metal plate constructing a plain portion (flat portion) located at lower side of the cylinder head gasket 1 , and is made from a mild steel plate, a stainless annealed material (anneal material), a stainless thermal refining material (spring steel plate) or the like for sealing the cooling water and the lubricating oil. Engaging holes 11 are provided for installing the bore sealing plate 20 around the holes 2 for the cylinder bores.
The bore sealing plate 20 is a ring-shaped plate having the full bead 21 to seal a periphery of the hole 2 for the cylinder bore, and is made from a mild steel plate, a stainless annealed material (anneal material), a stainless thermal refining material (spring steel plate) or the like for sealing the combustion gas and the cooling water. The ring-shaped bore sealing plate 20 is installed in the engaging hole 11 in the lower plate 10 for sealing the periphery of the hole 2 for the cylinder bore. A material of the bore sealing plate 20 may be different from the materials of the other plates 10 and 30 . Even if the material of the bore sealing plate 20 is the same as the other plates 10 and 30 , a step may be provided by making the plate thickness thicker.
The upper plate 30 is a metal plate constructing an upper side of the cylinder head gasket 1 , and is made from a mild steel plate, a stainless annealed material (anneal material), a stainless thermal refining material (spring steel plate) or the like for sealing the combustion gas, the cooling water, and the lubricating oil. The second full beads 31 are provided around the holes 2 for the cylinder bores in the upper plate 30 .
In the structure of the cylinder head gasket in FIGS. 1 to 8 , the first full beads 21 and the second full beads 31 are formed to project toward inner side of the cylinder head gasket 1 and the projecting portions are installed to face each other. The present invention is not limited to the sealing means with the structure.
In the present invention, as shown in FIG. 2 , a claw portion 12 is provided in the lower plate 10 . The claw portion 12 is formed to project with a tongue piece shape at the periphery of the engaging hole 11 or to cut into the periphery portion of the engaging hole 11 with the tongue piece shape (U-shape). In FIG. 2 , a part of the claw portion 12 on the tip is formed to project toward the inner side from the periphery of the engaging hole 11 .
When the claw portion 12 is formed by cutting the periphery of the engaging hole 11 with a tongue piece shape (U-shape), it is preferable that an enough width is allowed in the cutting portion to have a space S around the claw portion 12 . Thus, even if a pressure is applied to an insert portion of the claw portion 12 into the fixation hole 22 after the lower plate 10 and the bore sealing plate 20 are connected, a great shearing force can be prevented from being applied to vicinity of the base portion of the claw portion 12 to thereby prevent a shearing failure of the lower plate 10 by the shearing force.
As shown in FIG. 3 , the fixation hole 22 is provided in a projecting portion 23 outside from the outer periphery of the bore sealing plate 20 . The fixation hole 22 allows the claw portion 12 of the lower plate 10 to enter from the lower side of the bore sealing plate 20 and project toward the other side (upper side in FIG. 5 ), and the projecting portion is bent in a crank shape so that the claw portion 12 is engaged at the end portion therein.
Furthermore, as shown in FIG. 4 , an opening 32 is provided at a local connecting portion of the claw portion 12 and the fixation hole 22 , i.e. a portion located at the upper side of the claw portion 12 in the upper plate 30 . The opening 32 stores the cranked claw portion 12 in the opening portion to thereby prevent the claw portion 12 engaging the circumference of the fixation hole 22 , i.e. the connecting portion, from abutting against the upper plate 30 . Thus, a significant high surface pressure is prevented from being locally generated at the portion by the opening 32 .
In regard to the claw portion 12 , the fixation hole 22 , and the opening 32 , in a state that the claw portion 12 is inserted into the fixation hole 22 , in order to prevent the claw portion 12 from coming off from the fixation hole 22 when the lower plate 10 and the bore sealing plate 20 slide past each other relatively, it is preferable that the claw portion 12 and the fixation holes 22 are provided to be a pair around the bore sealing plate 20 and furthermore to provide the claw portions 12 to face in the opposite directions back-to-back. Also, the pairs of the claw portion 12 and the fixation hole 22 are preferably provided in not only one direction, but also more than two directions crossing each other.
As show in FIG. 5 , when the lower plate 10 and the bore sealing plate 20 are connected, the claw portion 12 of the lower plate 10 is stood near-upright to thereby be inserted into the fixation hole 22 in the bore sealing plate 20 . The end portion of the claw portion 12 projecting toward the other side is cranked so that the lower plate 10 and the bore sealing plate 20 are connected.
The upper plate 30 is provided on the two plates connected each other. The upper plate 30 is combined with the two plates by clinching, riveting, folding back, welding, and the like.
FIG. 6 shows a case that the lower plate 10 and the bore sealing plate 20 are connected at a side of the bore sealing plate 20 with a structure that the claw portion 12 is provided to project toward an inner side from the inner periphery of the engaging hole 11 in the lower plate 10 . Also, the fixation hole 22 is provided at an inner side from the outer periphery of the bore sealing plate 20 . Thus, the lower plate 10 and the bore sealing plate 20 can be connected at a side of the lower plate 10 . Although not shown in FIG. 6 , the claw portion 12 is provided not to project toward inner side from the inner periphery of the engaging hole 11 in the lower plate 10 , and is provided at the inner periphery of the engaging hole 11 by cutting the periphery of the engaging hole 11 . Also, the fixation hole 22 is provided to significantly project from the outer periphery of the bore sealing plate 20 . Thus, the claw portion 12 can be connected at the lower plate side. A proper connecting portion can be selected according to the outer periphery of the bore sealing plate 20 by selecting properly a structure from the structures described above.
According to the cylinder head gasket 1 with the structure described above, the two plates of the lower plate 10 and the bore sealing plate 20 can be connected by a simple operation to thereby attain automation easily. Furthermore, the upper plate 30 covering the upper side of the claw portion 12 is provided with the opening 32 at the portion facing the claw portion 12 . Thus, the claw portion 12 can be prevented from abutting against the upper plate 30 to thereby prevent the local surface pressure from increasing at the connecting portion.
In the above explanation, the lower plate 10 is regarded as the one of the metal constituting plates provided with the claw portion, and the bore sealing plate 20 is regarded as the other metal plate provided with the fixation hole. However, the bore sealing plate 20 may be regarded as the one of the metal constituting plates provided with the claw portion, and the lower plate 10 may be regarded as the other metal constituting plate provided with the fixation hole. Also, the connecting structure described above can be employed not only to the bore sealing plate 20 for sealing the hole 2 for cylinder bore, but also a sealing plate (not shown) for sealing the water holes 3 and oil holes 4 as well as the bore sealing plate 20 .
As other embodiments, FIG. 7 shows a case that the claw portion 12 of the lower plate 10 is connected to the bore sealing plate 20 by a welding 40 . FIG. 8 shows another case that the lower plate 10 is connected to the bore sealing plate 20 by butt spot-welding 40 .
In the cases described above, the connecting portion having the thickness increased by the welding 40 is prevented from abutting against the upper plate 30 to thereby prevent the local surface pressure from increasing at the connecting portion.
The disclosure of Japanese Patent Application No. 2005-306894 filed on Oct. 21, 2005 is incorporated as a reference.
While the invention has been explained with reference to the specific embodiments of the invention, the explanation is illustrative and the invention is limited only by the appended claims.
|
A metal laminate gasket is formed of at least three metal plates, i.e. first to third metal plates assembled together. A connecting portion is formed for partially connecting the first and second metal plates. The third metal plate has an opening located at a position facing the connecting portion for receiving the connecting portion therein. Thus, local pressure formed at the connection portion when the gasket is tightened is eliminated.
| 5
|
This is a continuation application Ser. No. 779,761, filed Mar. 21, 1977, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to centrifugal separators, in particular, centrifugal separators for removing solid particles from a liquid phase by the use of centrifugal force, for example a centrifugal separator for cleaning lubricating oil.
SUMMARY OF THE INVENTION
According to the present invention, a centrifugal separator assembly includes a cyclone extending into a stem and a centrifuge chamber mounted on and capable of rotation about the stem, and passages for leading fluid into the cyclone and thence into the centrifuge chamber, and out. Preferably a substantial part of the axial length of the cyclone is co-extensive with a substantial part-perhaps one half-of the axial length of the centrifuge chamber.
Preferably, the passage connecting the cyclone and the centrifuge is a throttling passage, and it may be situated at or near the top of the chamber. In addition the passage for leading fluid into the cyclone and/or the passage for leading fluid out may also be a throttling passage to enable desired pressures to be established in the system. Preferably the cyclone also has a direct liquid outlet other than through the centrifuge.
The chamber may be provided with at least one tangentially-directed reaction jet for rotating it.
A centrifugal separator according to the invention may be used for cleaning lubricating oil for example in an engine. In this case, clean oil from the cyclone may be returned to the lubricating circuit while the clean oil from the centrifuge chamber may be returned to the engine sump.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be carried into practice in various ways, and one embodiment will be described by way of example with reference to the accompanying drawings in which the single FIGURE is a vertical section through a centrifugal separator assembly according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The centrifugal separator comprises a cyclone and a centrifuge, shown generally at 10 and 11 respectively. The base 12 of the assembly, which is of cast aluminium, is integral with the cyclone and is attached to the external casing 13 by a clamping ring 14.
The upper portion 15 of the cyclone is generally conical in shape and has a conical apex 15a on which the centrifuge is mounted. The upper portion is formed from steel and provides the location for the centrifuge sleeve which is mounted on bearings 16 and 17. Passages 18 and 19 extend through the upper steel portion of the cyclone and communicate with the separation chamber 21 in the centrifuge via orifices 20 in the centrifuge. Separation chamber 21 is separated into upper and lower parts by a partition 30, 31 which includes a passage 32, 33 at the radial extremity thereof.
The top steel portion 15 of the cyclone screws down on to the bottom aluminium casting at the threaded section 28.
The cyclone is provided with a tangential oil inlet 24 and an axially disposed vortex finder 22 in its cylindrical end or base which provides an exit 23 for some of the cleansed oil on its return to the engine or machine.
Due to the shape of the cyclone, the factor V R remains constant all the way from the vortex finder 22 to the conical apex 15a at which point the particle velocity is greatly increased.
Two orifices 25 and 26 are located in the bottom bowl, or lower chamber of the separation chamber 21 so that any fluid issuing from them will set up a driving couple which will cause the centrifuge rotor to rotate.
When the centrifugal separator is in operation the contaminated oil mixture enters under pressure at inlet 24 and whirls around the vortex finder 22 and thence up the wall 15b of the cyclone 10 to the conical apex 15a. Cleansed oil tends to migrate to the centre of the vortex finder and is then directed to the engine or machine function. The contaminated mixture continues from the apex 15a through passages 18 and 19 to issue into the centrifuge through the orifices 20.
The action of the centrifuge causes the sludge from the mixture to move on to the inner cylindrical wall of the centrifuge rotor where it adheres evenly over the surface with a rubber-like consistency. The clean oil flows down into the bowl of the rotor where it issues through the orifices 25 and 26 to set up the driving couple for the rotor. The clean oil then returns to the sump via passage 27.
The drawing shows that a substantial part of the axial length of the cyclone is co-extensive with a substantial part about one-half- of the axial length of the centrifuge chamber, which makes for a very compact arrangement.
|
A centrifugal separator for removing a dispersed solid from a liquid phase by the combined action of a cyclone and a centrifuge, the centrifuge being mounted co-axially on the cyclone.
| 1
|
TECHNICAL FIELD
[0001] The present disclosure relates to a method for osteogenic differentiation on a synthetic bio-gel in a short time in the osteogenic differentiation induction of mesenchymal stem cells.
BACKGROUND ART
[0002] Due to the recent developments of tissue engineering and regenerative medicine, methods capable of treating damaged tissues and organs are being developed in a different manner from the conventional methods, and the cell therapy by mesenchymal stem cells is receiving most attention. Stem cells refer to cells that can proliferate indefinitely in an undifferentiated state as well as differentiating to have a specialized function and shape under specific environments and conditions. Examples of stem cells are: embryonic stem cells derived from human embryos; and adult stem cells, such as bone marrow cells that constantly generate blood cells. Embryonic stem cells can differentiate into all the cells and tissues constituting the human body, but the use thereof is limited for ethical reasons. Adult stem cells, on the other hand, are extracted from the umbilical cord blood or the bone marrow and blood of fully grown adults, enable the differentiation into specific tissues and organs after in vivo transplantation, and have the differentiation flexibility to transdifferentiate into cells of other tissues different from characteristics of original cells. Adult cells are widely used in tissue engineering without ethical limitations. In recent years, various attempts and early clinical trials are on the way in the medical field for the regeneration and replacement of tissues or organs of patients by growing stem cells and then differentiating the stem cells into specific cells. Mesenchymal stem cells are one type of adult stem cells present in various organs or blood of the body after the development and are a cell source that is easy to maintain and has no ethical problems. The mesenchymal stem cells are currently the most notable stem cell in the regenerative medicine field, but have a drawback in that the mesenchymal stem cells have limits in the in vitro subculture and differentiation potency compared with embryonic stem cells.
[0003] Studies on humans and animals have already confirmed that bone marrow-derived stem cells out of adult stem cells differentiate into osteogenic cells (Friedenstein A. J. et al., Transplantation., 6:230-247, 1968), and recent studies have progressed methods for culturing stem cells isolated from the bone marrow to differentiate the stem cells into osteoblasts, and there is an increasing possibility of clinical application using the methods (Ohgushi H. et al., J. Biomed Mater Res., 48:913-927, 1999). Recently, methods for differentiation into osteocytes from mesenchymal stem cells have dominantly been studied.
[0004] On the other hand, methods for the culture and differentiation of cells in a two-dimensional well plate are currently most widely used in the differentiation in stem cells. However, there are recent paper reports that two-dimensional (monolayer) cell culture lowers cell functions and significantly changes morphology compared with three-dimensional cell culture (Proc. Natl. Acad. Sci. USA, 100: 1943-1948, 2003; Cell, 111: 923-925, 2002; Cancer Cell 2: 205-216, 2002). The cell culture and differentiation in a manner of adversely affecting the state of cells as described above causes difficulty in differentiation and takes a long time. In order to overcome the drawbacks of such cell culture, Korean Patent No. 10-0733914 discloses a three-dimensional microcellular culture system characterized in that cells are present in a three-dimensional gel, but the gel needs to be dissolved in order to separate the cells present in the gel after the culture or differentiation of stem cells, causing severe cell damage.
DETAILED DESCRIPTION OF THE INVENTION
Technical Problem
[0005] The osteogenic differentiation induction in the conventional two-dimensional cell culture container has drawbacks in that only a portion of the stem cell is in contact with the medium, and thus, the inflow of nutrients, inductive ingredients, and air necessary for differentiation is not easy, thereby making the differentiation harder and causing the differentiation period to be longer, such as three to five weeks. A conventional three-dimensional culture method in which the cells are cultured inside a gel has a drawback in that cells cannot be separated. Accordingly, there is a need to develop a three-dimensional cell culture system that facilitates the separation and use of differentiated cells after osteogenic differentiation of stem cells.
Technical Solution
[0006] Therefore, in order to increase the contact surface area of cells with the medium to promote osteogenic differentiation while easily separating the cells, an aspect of the present disclosure is to provide a method in which cells exist inside a cell culture container in a non-contact manner and are in contact with the medium in all directions to promote osteogenic differentiation, thereby shortening the period for osteogenic differentiation.
Advantageous Effects
[0007] In cases where the osteogenic differentiation of stem cells is performed using the method for inducing osteogenic differentiation of stem cells of the present disclosure, the stem cells can be in contact with the medium with a wider surface area, thereby promoting the osteogenic differentiation induction of stem cells, thus remarkably shortening the period for osteogenic differentiation induction compared with the conventional method for osteogenic differentiation; and although the cells adhere to internal and external surfaces of the hydrogel, a gel-phase hydrogel is changed into a sol phase at a temperature below the cell culture temperature, 37° C., and thus, the cells can be easily separated even after differentiation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a schematic diagram showing a method for the differentiation of stem cells in a three-dimensional state according to the present disclosure.
[0009] FIG. 2 is a schematic diagram showing a method for the differentiation of stem cells in a two-dimensional state using a culture dish according to the conventional art.
[0010] FIG. 3 is a schematic diagram showing a method for three-dimensional differentiation of stem cells using only a polymer membrane without a hydrogel.
[0011] FIG. 4 confirms the osteogenic differentiation of bone marrow-derived mesenchymal stem cells, induced by the method of Comparative Example 1 (14 days: control 1, 5 days: control II), the method of Comparative Example 2 (lane 3, hydrogel concentration 0%), and the method of Example.
[0012] FIG. 5 confirms the osteogenic differentiation of bone marrow-derived mesenchymal stem cells, induced by the method of Comparative Example 1, the method of Comparative Example 2 (lane 2), and the method of Example.
[0013] FIG. 6 confirms the degrees of osteogenic differentiation of umbilical cord mesenchymal stem cells, induced by the method of Comparative Example 2 (control), the method of Comparative Example 2+100 ng/ml BMP2or 20 ng/ml Wnt3a, and the method of Example.
[0014] FIG. 7 confirms the degrees of osteogenic differentiation of umbilical cord mesenchymal stem cells, induced by the method of Example for 1 day, 3 days, 5 days, or 7 days.
[0015] FIG. 8 shows the results of osteogenic differentiation induction of bone marrow-mesenchymal stem cells (BMMSC), adipose-derived mesenchymal stem cells (ADMSC), umbilical cord mesenchymal stem cells (UCMSC), embryonic stem cell-derived mesenchymal stem cells (ESMSC), and periodontal ligament cells (PDL) by the method of Comparative Example 1, the method of Comparative Example 2 (without hydrogels), and the method of Example.
BEST MODE FOR CARRYING OUT THE INVENTION
[0016] Hereinafter, the present disclosure will be described in detail with reference to the following examples. However, the present disclosure may be realized in various different forms, and therefore is not limited to embodiments to be described herein.
[0017] In accordance with an aspect of the present disclosure, there is provided a method for inducing osteogenic differentiation of stem cells in a cell culture container inside which a porous membrane having one surface coated with a hydrogel is placed in a non-contact manner.
[0018] In an embodiment, the present disclosure may induce the osteogenic differentiation of stem cells, by including:
[0019] placing a porous membrane inside a cell culture container in a non-contact manner;
[0020] applying a hydrogel solution on one surface of the porous membrane to coat a hydrogel thereon through a sol-gel phase transition;
[0021] seeding stem cells on the coated hydrogel; and
[0022] culturing the stem cells in an osteogenic differentiation inducing medium.
[0023] In an embodiment, the method may further include a step of, before the culturing of stem cells in an osteogenic differentiation inducing medium after the seeding of stem cells, culturing the stem cells in an osteogenic differentiation pre-treatment medium for 10-24 hours. The pre-treatment medium may have a glucose concentration of 1.5 g/l or less.
[0024] In an embodiment, the porous membrane may be placed in parallel with the bottom of the cell culture container in a non-contact manner. The order of the coating of the hydrogel on the porous membrane and the placing of the porous membrane inside the cell culture container in a non-contact manner is not particularly limited. In such a case, the porous membrane may be disposed above the bottom of the cell culture container in a non-contact manner and then the hydrogel may be coated thereon, or the hydrogel may be coated on the porous membrane in advance and then the coated porous membrane may be disposed inside the cell container in a non-contact manner.
[0025] The cell culture container of the present disclosure generally refers to a dish or well plate used for cell culture, and the cell culture container is not particularly limited as long as it is used for cell culture and can introduce a porous membrane to the container bottom in a non-contact manner.
[0026] In an embodiment, in cases where cells are non-horizontally cultured inside the cell culture container to induce the osteogenic differentiation of stem cells, a hydrogel solution may be applied on one surface of the porous membrane, the cells may be allowed to adhere to the hydrogel, and then the resulting membrane may be placed inside the cell culture container in a non-contact manner to induce the osteogenic differentiation.
[0027] In an embodiment, the stem cells may be cultured in osteogenic differentiation inducing medium for 3-7 days.
[0028] In an embodiment, the medium flows in between the porous membrane and the cell culture container to increase the contact surface area between the stem cells and the medium, thereby shortening the period for osteogenic differentiation induction. The porous membrane and the hydrogel of the present disclosure allow the permeation of air and medium, and the medium flow in to fill a space between the porous membrane and the cell culture container, which is generated by disposing the porous membrane and the cell culture container in a non-contact manner, so that the medium and the air flow into even the adhering portion of the cells, and thus, the stem cells are in contact with the medium and air with a wider surface area, thereby shortening the time for osteogenic differentiation induction. For example, the existing osteogenic differentiation method takes three to five weeks, but the osteogenic differentiation by the method of the present disclosure occurs within 3-7 days.
[0029] The cell culture container of the present disclosure generally refers to a dish or well plate used for cell culture, and the cell culture container is not particularly limited as long as it is used for cell culture and can introduce a porous membrane to the container in a non-contact manner.
[0030] In an embodiment, the sol-gel phase transition of the hydrogel solution (hydrosol) into the hydrogel may be performed at 37□ for 1 to 2 hours.
[0031] In an embodiment, the hydrogel may include 1-40% hydrogels, and more preferably 1-15% hydrogels. The differentiation of stem cells does not occur for 0% hydrogel, and the efficiency of osteogenic differentiation does not increase and thus is not meaningful for 40% or more hydrogels. However, the concentration of the hydrogel is not limited thereto.
[0032] In an embodiment, the 1-40% hydrogels may be coated on the porous membrane at 200-300 μl /cm 2 , and the thickness of the hydrogels formed through the sol-gel phase transition may be 1-4 mm.
[0033] In an embodiment, the viscosity at 37□ of the hydrogel may be 1·E+00 to 1·E+06 (10 0 to 10 6 ) mPa·s depending on the concentration (%) of the hydrogel. In the hydrogel having a pore size out of the range, the adhesion or differentiation of stem cells may be difficult. The hydrogel of the present disclosure is in a gel phase at a cell culture temperature, 37□, and thus the cells are cultured inside and outside the gel. The hydrogel of the present disclosure is changed into a sol phase at a temperature lower than the cell culture temperature, thereby facilitating the separation of cells after cell differentiation.
[0034] In an embodiment, the porous membrane may have a pore size of 0.1-8 μm, but the pore size is not limited as long as the pore size is such that medium and air can pass through the porous membrane but the hydrogel cannot pass through the porous membrane.
[0035] In an embodiment, the stem cells may be umbilical cord mesenchymal stem cells, adipose-derived mesenchymal stem cells, embryonic stem cell-derived mesenchymal stem cells, periodontal ligament cells, or bone marrow-derived mesenchymal stem cells. The origins of the stem cells are not particularly limited, and examples thereof may be cells derived from human, monkey, pig, horse, cow, sheep, dog, cat, mouse, or rabbit. The stem cells are preferably human-derived stem cells, but are not limited thereto.
[0036] As used herein, the term “porous membrane” or “polymer membrane” refers to a porous membrane, a permeable membrane, or film type material through which medium or air passes but the hydrogel fails to pass. Any porous structure through which the cell culture medium and the air pass is not particularly limited.
[0037] As used herein, the term “hydrogel” refers to a material wherein a liquid, containing water as a dispersion medium, is solidified through a sol-gel phase transition to lose fluidity and form a porous structure. Any hydrogel suitable for cell adhesion and culture is not particularly limited, and in one embodiment of the present disclosure, a biodegradable synthetic bio-gel was used.
[0038] As used herein, the term “stem cells” refers to undifferentiated cells having self-renewal and differentiation potency. Stem cells include sub-groups of pluripotent stem cells, multipotent stem cells, and unipotent stem cells, according to their differentiation capacity. The pluripotent stem cells mean cells that have the potency to differentiate into all tissues or cells constituting a living organism, and the multipotent stem cells means cells that do not have potency to differentiate into all kinds but into plural kinds of tissues or cells. Unipotent stem cells mean cells that have the potency to differentiate into a particular tissue or cell. The pluripotent stem cells may include embryonic stem cells (ES cells), embryonic germ cells (EG cells), induced pluripotent stem cells (iPS cells), etc. The multipotent stem cells may include adult stem cells, such as mesenchymal stem cells (derived from fat, bone marrow, umbilical cord blood, or umbilical cord, etc.), hematopoietic stem cells (derived from bone marrow or peripheral blood), neural stem cells, germ stem cells, etc. The unipotent stem cells may include committed stem cells for hepatocytes, which are usually quiescent with low self-renewal capacity, but vigorously differentiate into hepatocytes under certain conditions.
[0039] In accordance with an aspect of the present disclosure, there is provided an apparatus for the differentiation of stem cells, the system including:
[0040] a cell culture container; and
[0041] a porous membrane configured to have one surface to which a hydrogel is attached, cells being to adhere to the hydrogel,
[0042] wherein the hydrogel-attached porous membrane is disposed inside the cell culture container in a non-contact manner.
[0043] In an embodiment, the porous membrane and the hydrogel may allow the permeation of air and medium.
Mode for Carrying Out the Invention
[0044] The present disclosure will be described in more detail through the following examples. However, the following examples are provided merely to illustrate the present disclosure and not to restrict the scope of the present disclosure.
EXAMPLE
Example 1
Stem Cell Differentiation Method in Three-Dimensional State
[0045] In order to promote the differentiation of stem cells, the trial for three-dimensional differentiation was performed. To this end, a polymer membrane with a thickness of 0.4-1 μm (Corning, USA) was provided so as to be horizontal to the bottom of a cell culture dish or well in a non-contact manner. A biodegradable synthetic bio-gel (BASF, Germany) was dissolved in sterilized tertiary distilled water to prepare gels with various concentrations (%). Then, 250 μl/cm 2 of the prepared biodegradable synthetic bio-gels were coated on the polymer membranes, and then solidified at 37° C. for 1 hour and 30 minutes, thereby manufacturing cell culture containers. The thickness of the biodegradable synthetic bio-gel after the sol-gel phase transition was at least 1 mm, and the average was 2.5 mm. The adipose-derived mesenchymal stem cells in CEFOgro ADMSC medium (CB-ADMSC-GM, CEFO, Korea), the bone marrow-derived mesenchymal stem cells in CEFOgro BMMSC medium (CB-BMMSC-GM, CEFO, Korea), the embryonic stem cell-derived mesenchymal stem cells in CEFOgro ESMSC medium (CB-ESMSC-GM, CEFO, Korea), the umbilical cord mesenchymal stem cells in CEFOgro UCMSC medium (CB-UCMSC-GM, CEFO, Korea), the periodontal ligament cells (PDL) in CEFOgro PDL medium (CB-PDL-GM, CEFO, Korea) were cultured in the CO 2 incubator at 37° C. for 3-4 days. Thereafter, each type of stem cells was seeded on the bio-gel, and the osteogenic differentiation pre-treatment medium (CB-DM-Osteo-PT, CEFO, Korea) was added thereto, followed by culture in the CO 2 incubator at 37□ for 18 hours. Thereafter, the medium was exchanged with osteogenic differentiation inducing medium (CB-DM-Osteo, CEFO, Korea), and then the osteogenic differentiation was induced in the CO 2 incubator at 37□ for 5 days ( FIG. 1 ).
Comparative Example 1
Stem Cell Differentiation Method in Two-Dimensional State
[0046] Stem cells were differentiated by a two-dimensional differentiation method, which is the conventional stem cell differentiation method. Specifically, the cells were seeded in the 12-well cell culture container (dish), and cultured in the pre-treatment medium (CB-DM-Osteo-PT, CEFO, Korea) for inducing osteogenic differentiation until the cell density reaches 85-90%. Thereafter, the medium was exchanged with the osteogenic differentiation inducing medium (CB-DM-Osteo, CEFO, Korea), followed by osteogenic differentiation induction for 14-21 days ( FIG. 2 ).
Comparative Example 2
Stem Cell Differentiation Method in Three-Dimensional State Without Hydrogel
[0047] In order to investigate the differentiation of stem cells when the biodegradable synthetic bio-gel on the polymer membrane in Example 1 is 0% (only polymer membrane is present), stem cells were seeded on the polymer membrane, and then cultured for 5 days like in Example 1 ( FIG. 3 ).
Test Example 1
Verification on Osteogenic Differentiation of Bone Marrow-Derived Mesenchymal Stem Cells
[0048] The bone marrow-derived mesenchymal stem cells undergoing osteogenic differentiation induced by the method of Comparative Example 1 for 14 days or 5 days, the bone marrow-derived stem cells undergoing osteogenic differentiation induced by the method of Comparative Example 2 (0% biodegradable synthetic bio-gel) for 5 days, and the bone marrow-derived stem cells undergoing osteogenic differentiation induced by the method of Example above (5%, 10%, or 15% biodegradable synthetic bio-gel) were visually observed for osteogenic differentiation through a phase contrast microscope. In addition, in order to investigate the osteogenically differentiated cells through Alizarin red staining, the cells were washed twice with PBS, fixed with 70% ethyl alcohol at room temperature for 10 minutes, and then washed twice with tertiary distilled water. Thereafter, the cells were treated with Sol I of Alizarin Red staining kit (CB-SK-Osteo), followed by reaction at room temperature for 30 minutes. Thereafter, the cells were cleanly washed three times with Sol II, and subjected to image analysis using an inverted microscope (LEICA, Germany). In addition, for digitization of the results, the cells were treated with Sol III after image synthesis to perform a reaction for 30 minutes, so that the stained reagent was completely dissolved. Then, 100 μl of the dissolved solution was taken, placed in a 96-well plate, and the absorbance was measured at 550 nm. As a result, the osteogenic differentiation was not attained when the osteogenic differentiation was induced by the method of Comparative Example 1 for 5 days and when the osteogenic differentiation was induced by the method of Comparative Example 2 for 5 days, but sufficient osteogenic differentiation was induced when the osteogenic differentiation was induced by the method of Example for 5 days. Especially, it could be seen that, with respect to the osteogenic differentiation by the method of Example above, the osteogenic differentiation occurred favorably in all the 1 to 30% hydrogels, and the most optimal osteogenic differentiation was shown at a concentration of 10% ( FIG. 4 ).
Test Example 2
Verification on Osteogenic Differentiation of Adipose-Derived Mesenchymal Stem Cells
[0049] The adipose-derived mesenchymal stem cells undergoing osteogenic differentiation induced by the method of Comparative Example 1 for 14 days, the bone marrow-derived stem cells undergoing osteogenic differentiation induced by the method of Comparative Example 2 (0% biodegradable synthetic bio-gel) for 5 days, and the bone marrow-derived stem cells undergoing osteogenic differentiation induced by the method of Example above (5%, 10%, or 15% biodegradable synthetic bio-gel) were visually observed for osteogenic differentiation through a phase contrast microscope. In addition, in order to investigate the osteogenically differentiated cells through Alizarin red staining, the cells were washed twice with PBS, fixed with 70% ethyl alcohol at room temperature for 10 minutes, and then washed twice with tertiary distilled water. Thereafter, the cells were treated with Sol I of Alizarin Red staining kit (CB-SK-Osteo), followed by reaction at room temperature for 30 minutes. Thereafter, the cells were cleanly washed three times with Sol II, and subjected to image analysis using an inverted microscope (LEICA, Germany). As a result, it could be seen that the osteogenic differentiation never occurred when the osteogenic differentiation was induced by the method of Comparative Example 2 for 5 days, but when the osteogenic differentiation was induced by the method of Example for 5 days, the osteogenic differentiation was favorably attained in all the 1 to 30% biodegradable synthetic hydrogels, and the most optimal osteogenic differentiation was shown at a concentration of 5-10% ( FIG. 5 ).
Test Example 3
Verification on Osteogenic Differentiation of Umbilical Cord Mesenchymal Stem Cells
[0050] The umbilical cord mesenchymal stem cells undergoing osteogenic differentiation induced by the method of Comparative Example 2 for 5 days, the umbilical cord mesenchymal stem cells seeded by the method of Comparative Example 2, treated with 100 ng/ml bone morphogenic protein 2 (BMP 2, peprotech, israel) or 20 ng/ml Wnt3a (peprotech, israel), and then undergoing osteogenic differentiation induction for 5 days, the umbilical cord mesenchymal stem cells undergoing osteogenic differentiation induction by the method of Example above (10% biodegradable synthetic bio-gel) were visually observed for osteogenic differentiation through a phase contrast microscope. In addition, in order to investigate the osteogenically differentiated cells through Alizarin red staining, the cells were washed twice with PBS, fixed with 70% ethyl alcohol at room temperature for 10 minutes, and then washed twice with tertiary distilled water. Thereafter, the cells were treated with Sol I of Alizarin Red staining kit (CB-SK-Osteo), followed by reaction at room temperature for 30 minutes. Thereafter, the cells were cleanly washed three times with Sol I, and subjected to image analysis using an inverted microscope (LEICA, Germany). In addition, for digitization of the results, the cells were treated with Sol III after image synthesis to perform a reaction for 30 minutes, so that the stained reagent was completely dissolved. Then, 100 μl of the dissolved solution was taken, placed in a 96-well plate, and the absorbance was measured at 550 nm. As a result, the osteogenic efficiency was significantly excellent in the umbilical cord mesenchymal stem cells using the method of Example of the present disclosure rather than when the osteogenic differentiation was induced by the method of Comparative Example 2 for 5 days plus the treatment with BMP and Wnt3a known to promote osteogenic differentiation ( FIG. 6 ).
Test Example 4
Verification on Change Depending the Period for Osteogenic Differentiation of Umbilical Cord Mesenchymal Stem Cells
[0051] The umbilical cord mesenchymal stem cells undergoing osteogenic differentiation for 1, 3, 5, or 7 days by the method of Example above (10% biodegradable synthetic bio-gel) were subjected to image analysis through Alizarin red staining. In addition, for digitization of the results, the absorbance was measured at 550 nm. As a result, the induction of osteogenic differentiation began from the 1st day of osteogenic differentiation induction, and the osteogenic differentiation was stronger as the period for osteogenic differentiation was longer. Especially, the umbilical cord mesenchymal stem cells, which have been known to undergo less osteogenic differentiation in the conventional two-dimensional method compared with the other types of mesenchymal stem cells, showed favorable osteogenic differentiation in the three-dimensional osteogenic differentiation method of Example of the present disclosure, like the other types of mesenchymal stem cells ( FIG. 7 ).
Test Example 5
Verification on Osteogenic Differentiation of Various Types of Mesenchymal Stem Cells
[0052] Bone marrow-derived mesenchymal stem cells, adipose-derived mesenchymal stem cells, umbilical cord mesenchymal stem cells, embryonic stem cell-derived mesenchymal stem cells, and periodontal ligament cell were allowed to undergo the induction of osteogenic differentiation by the method of Comparative Example 1 for 14 days, the method of Comparative Example 2 (0% biodegradable synthetic bio-gel) for 5 days, or the method of Example above (10% biodegradable synthetic bio-gel) for 5 days, and then the degree of osteogenic differentiation of each type of mesenchymal stem cells was investigated through Alizarin red staining.
[0053] As a result, the osteogenic differentiation of the mesenchymal stem cells was not induced when the osteogenic differentiation was induced for 5 days by the method of Comparative Example 1 and the method of Comparative Example 2, but the osteogenic differentiation was favorably induced regardless of the origin of the mesenchymal stem cells when the osteogenic differentiation was three-dimensionally induced on the biodegradable synthetic bio-gel for 5 days ( FIG. 8 ).
[0054] As described above, it was verified that the osteogenic differentiation of mesenchymal stem cells takes about 2-5 weeks by the conventional two-dimensional osteogenic differentiation method, but the osteogenic differentiation occurs within 3-7 days when using the three-dimensional osteogenic differentiation method of the present disclosure of placing the polymer membrane above the cell culture container in a non-contact manner, coating the hydrogel thereon, seeding the mesenchymal stem cells thereon, culturing the mesenchymal stem cells in the osteogenic differentiation pre-treatment medium, and treating the mesenchymal stem cells with the osteogenic differentiation inducing medium.
|
The present invention relates to a method for inducing osteogenic differentiation of mesenchymal stem cells and, more particularly, to a short-time osteogenic differentiation method of culturing cells using a porous membrane and a biodegradable synthetic biogel, whereby the cells do not contact a cell culture container. The present invention can significantly shorten the induction period of osteogenic differentiation, compared to the conventional osteogenic differentiation method, and has an effect of the cells being easily separable after differentiation as well.
| 2
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is entitled to the benefit of British Patent Application No. GB 1004559.9, filed on Mar. 19, 2010.
FIELD OF THE INVENTION
[0002] The present invention relates to the analysis of rotating blades, such as those found in gas turbine engines.
BACKGROUND OF THE INVENTION
[0003] In the development of gas turbine engines, it is important to determine the amount of vibration of the rotating blades. From vibration measurements, stresses induced in the blades may be determined. Action can then be taken to avoid stresses which are high enough to cause damage to the blades.
[0004] A technique for characterising blade vibration is “blade tip timing” (BTT) in which non-contact timing probes (e.g. capacitance or optical probes), typically mounted on the engine casing, are used to measure the time at which a blade passes each probe. This time is compared with the time at which the blade would have passed the probe if it had been undergoing no vibration. This is termed the “expected arrival time” and can be calculated from the rotational position of the particular blade on the rotor in conjunction with a “once per revolution” (OPR) signal which provides information about the position of the rotor. The OPR signal is derived from the time at which an indicator on the rotor passes a reference sensor, and its use is well known in the art.
[0005] The difference between the expected arrival time and the actual arrival time can be multiplied by the blade tip velocity to give the displacement of the blade from its expected position. Thus BTT data from a particular probe effectively measures blade tip displacement at the probe.
[0006] Advantageously, the tip timing method does not require a telemetry system since the probes are mounted on the casing. However, because the sampling rate of the probes is determined by the rotational frequency of the rotor, it is often below the Nyquist frequency for the vibrations of interest. Thus each probe undersamples the vibrations, leading to problems such as aliasing. A further problem with BTT data is that it is often intrinsically noisy due to probe movement caused by mounting restrictions and casing thickness. Nonetheless, with a plurality of timing probes, it is possible, in principle, to perform useful vibration analysis that can be converted into blade stresses.
SUMMARY OF THE INVENTION
[0007] The present invention is at least partly based on a realisation that BTT data can be used to extract further useful information about rotating blades.
[0008] The external shape of blades, such as fan blades, can be defined by a series of aerofoil sections at different radial positions along the blade. These sections can have respective stagger angles (i.e. the angle between the chord at a particular section and the axial direction of the rotor) which increase with increasing radial position. Due to operating loadings such as centrifugal and aerodynamic forces, the blades can “unwind” in use, producing changes to the stagger angles. At the tip of a blade, this variation in stagger angle can be considered as a rotation of the chord at the tip about a blade stagger angle axis which extends in a radial direction of the rotor. To understand blade behaviour during operation, it would be desirable to be able to determine the instantaneous position of the blade stagger angle axis for a given blade. Similarly, it would be desirable to be able to determine the instantaneous blade stagger angle at the tip of a given blade.
[0009] Thus a first aspect of the invention provides a method of measuring the position of the blade stagger angle axis for one or more blades of a row of blades attached to a rotor, the method includes the steps of:
[0010] providing forward and rearward blade tip timing datasets for successive rotations of the blades from two axially spaced blade tip timing probes, the forward probe being forward of the rearward probe along the axial direction of the rotor, the blade tip timing datasets allowing the times of arrival of the blades at the respective probes to be measured;
[0011] providing a once per revolution dataset for said successive rotations of the blades, the once per revolution dataset allowing the angular velocity of the blades to be measured;
[0012] determining, from the forward and rearward blade tip timing datasets, the measured blade tip times of arrival at the forward and rearward probes of a blade for a reference revolution of the blades;
[0013] determining, from the once per revolution dataset, predicted blade tip times of arrival at the forward and rearward probes of the blade for a further revolution of the blades on the assumption that there is no change in shape or relative position of the blade;
[0014] determining, from the forward and rearward blade tip timing datasets, the measured blade tip times of arrival at the forward and rearward probes of the blade for said further revolution of the blades;
[0000] calculating the position of the blade stagger angle axis at said further revolution from the expression:
[0000] D FA =D FR (Δ F /(Δ F +Δ R ))
[0000] or from the expression:
[0000] D RA =D FR (Δ R /(Δ F +Δ R ))
[0015] where D FA is the distance along the axial direction of the rotor between the forward probe and the position of the blade stagger angle axis, D RA is the distance along the axial direction of the rotor between the rearward probe and the position of the blade stagger angle axis, D FR is the distance along the axial direction of the rotor between the forward probe and the rearward probe, Δ F is the difference between the measured time of arrival at the forward probe and the predicted time of arrival at the forward probe for said further revolution, and Δ R is the difference between the measured time of arrival at the rearward probe and the predicted time of arrival at the rearward probe for said further revolution.
[0016] A second aspect of the invention provides a method of measuring the blade tip stagger angle for one or more blades of a row of blades attached to a rotor, the method includes the steps of:
[0017] providing forward and rearward blade tip timing datasets for successive rotations of the blades from two axially spaced blade tip timing probes, the forward probe being forward of the rearward probe along the axial direction of the rotor, the blade tip timing datasets allowing the times of arrival of the blades at the respective probes to be measured;
[0018] providing a once per revolution dataset for said successive rotations of the blades, the once per revolution dataset allowing the angular velocity of the blades to be measured;
[0019] determining, from the forward and rearward blade tip timing datasets, the measured blade tip times of arrival at the forward and rearward probes of a blade for a revolution of the blades;
[0020] calculating the blade tip stagger angle of the blade at said revolution from
[0000] the expressions:
[0000] θ= a tan(( R ((α F −α R )−Δ α ))/ D FR )
[0000] and
[0000] Δ α =ω( T m F −T m R )
[0021] where θ minus the blade tip stagger angle of the blade at said revolution, D FR is the distance along the axial direction of the rotor between the forward probe and the rearward probe, R is the radial distance from the tip of the blades to the axis of the rotor, α F is the angular position of the forward probe, α R is the angular position of the rearward probe, ω is the measured angular velocity of the blades at said revolution, T m F is the measured time of arrival of the blade at the forward probe at said revolution, and T m R is the measured time of arrival of the blade at the rearward probe at said revolution.
[0022] Thus, by using blade tip timing data, it is possible to measure the instantaneous position of the blade stagger angle axis and/or to measure the instantaneous blade tip stagger angle for a particular blade. Advantageously, these measurements can be used in subsequent analyses. In particular, they can be used to determine the instantaneous blade tip axial displacement, i.e. displacement of the tip of the blade in the axial direction of the rotor. This displacement can be caused by operating loadings (e.g. centrifugal and aerodynamic forces) and/or by axial movement of the entire blade relative to the rotor, for example by sliding of a fan blade along its dovetail root fixing. Further, measurement of the stagger angle enables modellers to confirm the measurements of blade unwind against (e.g. finite element) model predictions.
[0023] Accordingly, a third aspect of the invention provides a method of measuring the blade tip axial displacement for one or more blades of a row of blades attached to a rotor, the method includes the steps of:
[0024] performing the method of the first aspect to measure the position of the stagger angle axis of a blade at said further revolution of the blades;
[0025] performing the method of the second aspect to measure the blade tip stagger angle for the blade at said reference revolution of the blades;
[0026] performing the method of the second aspect to measure the blade tip stagger angle for the blade at said further revolution;
[0027] determining updated predicted blade tip times of arrival at the forward and rearward probes of the blade for said further revolution from the expressions:
[0000] T P F,fur =T m F,ref ω ref /ω fur −D FA,fur (tan(θ fur )−tan(θ ref ))/( Rω fur )
[0000] and
[0000] T P R,fur =T m R,ref ω ref /ω fur +D RA,fur (tan(θ fur )−tan(θ ref ))/( Rω fur )
[0028] where T P R,fur and T P R,fur are the updated predicted times of arrival of the blade at respectively the forward and rearward probes at said further revolution and relative to the start of said further revolution, T m F,ref and T m R,ref are the measured times of arrival of the blade at respectively the forward and rearward probes at said reference revolution and relative to the start of said reference revolution, ω ref and ∩ fur are the measured angular velocities of the blades at respectively said reference revolution and said further revolution, D FA,fur and D RA,fur are the distances along the axial direction of the rotor between respectively the forward probe and the position of the blade stagger angle axis and the rearward probe and the position of the blade stagger angle axis at said further revolution, and θ ref and θ fur are the blade tip stagger angles of the blade at respectively said reference revolution and said further revolution;
[0029] and determining the blade tip axial displacement at said further revolution relative to the blade tip axial position at said reference revolution from the expressions:
[0000] Δ ax =(2 πRΔt cts )/(ω fur tan(θ fur ))
[0000] and
[0000] Δ t cts =( T m F,fur −T P F,fur )−( T m R,fur −T P R,fur )
[0030] where Δ ax is the blade tip axial displacement at said further revolution relative to the blade tip axial position at said reference revolution, and T m F,fur and T m R,fur are the measured times of arrival of the blade at respectively the forward and rearward probes at said further revolution and relative to the start of said further revolution.
[0031] The blade axial tip displacement measured in this way can be used, for example, in the validation of blade models (e.g. finite element models) and/or in BTT calibration. The displacement can also be used to understand, e.g. engine surge, stall and flutter events, and thus help in engine design.
[0032] Advantageously, the forward and rearward blade tip timing datasets and the once per revolution dataset used in the methods of the above aspects can be obtained without fixing probes to the blades. For example, the forward and rearward probes can be mounted on a casing of the rotor.
[0033] The method of any one of the first, second and third aspects can be repeated for other blades of the row. The method of any one of the first, second and third aspects may include an initial step of generating the forward and rearward blade tip timing datasets and the once per revolution dataset. For example, the forward and rearward blade tip timing datasets can be generated by detecting the times at which the blades pass the forward and rearward probes. The once per revolution dataset can be generated by detecting the times at which a marker on the rotor passes a once per revolution probe.
[0034] The method of any one of the first, second and third aspects may have any one or any combination of the following optional features. The blade may be a fan blade. The forward probe is typically at a position which is swept by the leading edges of the blades. The rearward probe is typically at a position which is swept by the trailing edges of the blades. The reference rotation may conveniently be the first rotation of the rotor.
[0035] Further aspects of the present invention provide: (i) use of the method of any one of the first, second and third aspects for validating a model (e.g. a finite element model) of the blades, (ii) use of the method of any one of the first, second and third aspects for calibrating blade tip timing data, and (iii) use of the method of any one of the first, second and third aspects for characterisation of surge, stall and/or flutter events.
[0036] Typically, the methods of the first, second and third aspects are computer-based methods. Further aspects of the present invention provide: (i) a computer-based system for performing the method of any one of the first, second and third aspects, (ii) a computer program for performing the method of any one of the first, second and third aspects, and (iii) a computer program product carrying a program for performing the method of any one of the first, second and third aspects.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] FIG. 1 shows schematically a BTT arrangement;
[0038] FIG. 2 is a flow chart showing procedural steps in a method of measuring the blade tip axial displacement of a blade of a row of blades attached to a rotor;
[0039] FIG. 3 shows schematically the measurement of the blade tip stagger angle if the blade at either a reference or a further rotation;
[0040] FIG. 4 shows schematically the measurement of the stagger angle axis of the blade at the further rotation;
[0041] FIG. 5 shows schematically rotation of the blade tip aerofoil section about the blade stagger angle axis;
[0042] FIG. 6 shows schematically a circumferential time shift of the blade tip and the corresponding blade tip axial displacement; and
[0043] FIG. 7 shows plots of measured blade tip axial displacement against rotor speed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0044] FIG. 1 shows schematically a BTT arrangement. An OPR probe 1 monitors the position of rotor 2 , while 1 to n BTT probes 3 provide timings for blades 4 mounted to the rotor.
[0045] FIG. 2 is a flow chart showing procedural steps in a method of measuring the blade tip axial displacement of a blade of a row of blades attached to a rotor.
[0046] In a first step 5 , BTT datasets are generated for (i) a forward BTT probe positioned so that it is swept by the leading edges of a row of blades over successive rotations of the blades and (ii) a rearward BTT probe positioned so that it is swept by the trailing edges of the blades over the rotations. An OPR dataset is also generated for the successive rotations. The data in the datasets do not have to be filtered. In a next step 6 , the datasets are used to measure the blade tip stagger angle for one of the blades and on a reference rotation (conveniently the first rotation) of the blades. At step 7 , the datasets are used to measure the blade tip stagger angle for the blade on a further rotation of the blades. At step 8 , the datasets are used to measure the position of the stagger angle axis of the blade at the further revolution. At step 9 , the blade tip stagger angles and the position of the stagger angle axis are used to determine predicted blade tip times of arrival at the forward and rearward probes for the further revolution. Finally, at step 10 , the predicted blade tip times of arrival are used to determine the blade tip axial displacement at the further revolution.
[0047] 0291 Returning to steps 6 and 7 , FIG. 3 shows schematically the measurement of the blade tip stagger angle at either the reference or further rotation. A blade tip 11 sweeps at an angular velocity w passed the forward probe 12 at angular position α F and rearward probe 13 at angular position α R , the distance along the axial direction of the rotor between the forward and rearward probes being D FR . The angular shift Δ α , of the leading or trailing edge of the blade between the arrivals at the forward and rearward probes is then:
[0000] Δ α =ω( T m F −T m R )
[0048] where T m F is the measured time of arrival of the blade at the forward probe from the forward probe BTT dataset, and T m R is the measured time of arrival of the blade at the rearward probe from the rearward probe BTT dataset. The blade tip stagger angle θ, i.e. the angle between the chord C of the aerofoil section at the blade tip 11 and the axial direction X of the rotor, is then calculated for the particular revolution from the expression:
[0000] θ= a tan(( R ((α F −α R )−Δ α ))/ D FR )
[0049] where R is the radial distance from the tip of the blades to the axis of the rotor.
[0050] Turning then to step 8 , FIG. 4 shows schematically the measurement of the blade stagger angle axis at the further rotation. On the assumption that there is no change in shape or relative position of the blade (i.e. there are no geometric or aerodynamic changes), predicted blade tip times of arrival at the forward and rearward probes of the blade for the further revolution are calculated from the angular velocity of the blades as measured by the OPR dataset. These predicted blade tip times of arrival are represented in FIG. 4 by a predicted chord position for the blade. The BTT datasets, however, provide the actual measured blade tip times of arrival at the forward and rearward probes of the blade for the further revolution. These measured blade tip times of arrival are represented in FIG. 4 by a measured chord position for the blade. Also shown in FIG. 4 are lines F, R respectively which are the paths swept by the positions on the blade tip corresponding to the forward 12 and rearward 13 probes, and the line S which is the path swept by the position on the blade tip through which the blade stagger angle axis passes
[0051] The position of line S and hence the position of the blade stagger angle axis is calculated from the expression:
[0000] D FA −D FR /(Δ F /Δ F +Δ R ))
[0000] or from the expression:
[0000] D RA =D FR (Δ R /(Δ F +Δ R ))
[0052] where D FA is the distance along the axial direction X of the rotor between the forward probe and the position of the blade stagger angle axis, D RA is the distance along the axial direction of the rotor between the rearward probe and the position of the blade stagger angle axis, D FR is the distance along the axial direction of the rotor between the forward probe and the rearward probe, Δ F is the difference between the measured time of arrival at the forward probe and the predicted time of arrival at the forward probe for said further revolution, and Δ R is the difference between the measured time of arrival at the rearward probe and the predicted time of arrival at the rearward probe for said further revolution.
[0053] Turning next to step 9 , the blade tip stagger angles at the reference and further rotations and the position of the stagger angle axis at the further rotation are used to establish updated predicted blade tip times of arrival at the forward and rearward probes for the further revolution. More particularly, by knowing the position of the stagger angle axis, the blade tip aerofoil section can be rotated about that axis by an amount corresponding to the change in stagger angle between the reference rotation and the further rotation, as shown schematically in FIG. 5 . That is:
[0000] T P F,fur =T m F,ref ω ref /ω fur −D FA,fur (tan(θ fur )−tan(θ ref ))/( Rω fur )
[0000] and
[0000] T P R,fur =T m R,ref ω ref /ω fur +D RA,fur (tan(θ fur )−tan(θ ref ))/( R ω fur )
[0054] where T P F,fur and T P R,fur are the updated predicted times of arrival of the blade at respectively the forward 12 and rearward 13 probes at the further revolution and relative to the start of the further revolution, T m F,ref and T m R,ref are the measured times of arrival of the blade at respectively the forward and rearward probes at the reference revolution and relative to the start of the reference revolution, ω ref and ω fur are the measured angular velocities of the blades at respectively the reference revolution and the further revolution, D F,fur and D RA,fur are the distances along the axial direction of the rotor between respectively the forward probe and the position of the blade stagger angle axis and the rearward probe and the position of the blade stagger angle axis at said further revolution, and θ ref and θ fur are the blade tip stagger angles of the blade at respectively said reference revolution and said further revolution.
[0055] At step 10 , from T P F,fur and T P R,fur it is then possible to calculate a circumferential time shift of the blade tip, Δt cts , from the expression:
[0000] Δt cts =( T m F,fur −T P F,fur )−( T m R,fur −T P R,fur )
[0056] where T m F,fur and T m R,fur are the measured times of arrival of the blade at respectively the forward and rearward probes at said further revolution and relative to the start of said further revolution. The circumferential time shift is based on an assumption that the aero gas loading on each blade is constant from leading to trailing edge. In this case any difference between (T m F,fur −T P F,fur ) and (T m R,fur −T P R,fur ) corresponds to a circumferential time shift of the blade tip that is caused by a displacement, Δ ax , of the blade tip in the axial direction X, as shown schematically in FIG. 6 . This displacement is calculated from the expression:
[0000] Δ ax =(2 πRΔt cts )/(ω fur tan(θ fur ))
[0057] Thus from relatively nonintrusive and simple instrumentation, i.e. two BTT probes and an OPR probe, blade tip axial displacements can be measured.
[0058] The method can be repeated for other revolutions so that the development of blade tip axial displacement can be followed or plotted. Likewise, the method can be repeated for other blades of the row of blades. The method is also suitable for obtaining measurements in real time.
[0059] The method can be used for model validation (e.g. finite element model validation), BTT calibration, and also for characterisation of surge, stall and flutter events.
[0060] FIG. 7 shows plots of blade tip axial displacement against rotor speed, the displacement being measured according to the above method for all blades of a row of blades. The upper plot shows the maximum displacement of the blades, the middle plot shows the mean displacement of the blades, and the bottom plot shows the minimum displacement of the blades.
[0061] While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention.
|
Methods are provided for: (i) measuring the position of the blade stagger angle axis for one or more blades of a row of blades attached to a rotor, (ii) measuring the blade tip stagger angle for one or more such blades, and (iii) measuring the blade tip axial displacement for one or more such blades. The methods use forward and rearward blade tip timing datasets for successive rotations of the blades from two axially spaced blade tip timing probes. The forward probe is forward of the rearward probe along the axial direction of the rotor. The blade tip timing datasets allow the times of arrival of the blades at the respective probes to be measured. The methods also use a once per revolution dataset for the successive rotations of the blades. The once per revolution dataset allows the angular velocity of the blades to be measured.
| 6
|
BACKGROUND OF THE INVENTION
This invention on relates to cleansing apparatus for use in a vehicle washing system.
Certain vehicle washing systems known to the applicant include elongate vertically mounted brushes which are suspended from overhead supports and which are rotatable about rigid vertically extending axes. A brush of this kind must be long enough to clean the external surface of any vehicle which is driven past it. Thus the length of the brush must be sufficient to accommodate the tallest vehicle which will be cleaned in the system.
The brush is usually suspended from its upper end. This carries with it the significant disadvantage that when a vehicle, which is substantially shorter than the vertical height of the brush, strikes the lower end, particularly if the vehicle is moving relatively fast, the brush can be bent about its vertical axis. The bending takes place because of the moment exerted by the vehicle on the lower end of the brush about the upper suspension point.
A second problem which is encountered with a rigidly suspended vertically aligned brush is that certain vehicles have sloping sides and, although the bristles of the brush are compressible at least to a limited extent in the radial direction, it is not always possible to clean the entire area of a sloping side.
SUMMARY OF THE INVENTION
The invention is concerned with improved cleansing apparatus which enables problems of the kind referred to to be minimised.
The invention provides a method of operating cleansing apparatus in a vehicle washing system which includes the steps of suspending a cleaning device from one end so that it can pivot relatively to the vertical in at least one direction, and of rotating the device about a longitudinal axis.
The longitudinal axis is nominally vertical. However the axis may be displaced from the vertical depending on the pivotal movement of the cleaning device.
In accordance with a preferred aspect of the invention the cleaning device is permitted to operate in a self-balancing state i.e. a condition in which it naturally takes up the axis about which it rotates.
Preferably the cleaning device is permitted to move pivotally in any direction relatively to the vertical. The extent of angular movement is variable, within practical limits, to meet requirements, and usually is of the order of up to 15°.
The invention also provides a method of operating cleansing apparatus in a vehicle washing system which includes the steps of mounting a cleaning device to a fixed structure, imparting a cleaning motion to the cleaning device, and permitting the cleaning device to move pivotally relatively to the fixed structure during the cleaning motion.
In one form of the method, with the cleaning motion, the cleaning device is caused to rotate about an axis of rotation and the orientation of the axis of rotation varies, or is permitted to vary, relatively to the fixed structure.
In a different embodiment, with the cleaning motion, the cleaning device is driven eccentrically and moves around an axis which passes through the fixed structure.
The invention also extends to cleansing apparatus for use in a vehicle cleaning system which includes a cleaning device, means for rotating the device about a longitudinal axis, and means for suspending the device with the longitudinal axis substantially vertical, the suspension means permitting pivotal movement of the cleaning device in at least one direction relatively to the vertical.
Preferably the cleaning device is permitted to move pivotally in all directions relatively to the vertical. The extent of angular movement may vary according to requirement and to practical restraints. Typically the cleaning device is permitted to move in all directions by at least up to 15° from the vertical.
The suspension means may take on any suitable form. For example the suspension means may include a universal coupling, a ball and socket joint, or the like. If use is made of a universal type coupling then this is preferably located above the rotating means. The suspension means may also comprise a resilient support e.g. of rubber or other flexible material or components which permit the cleaning device to move away from the vertical, as may be necessary.
In one example of the invention the suspension means includes an upwardly facing concave socket which is formed with an aperture, a ball which includes an external surface which is shaped complementary to the concave socket surface, a shaft which passes through the ball and the aperture, the ball and the shaft being movable in the socket in such a way that the shaft is movable laterally relatively to the vertical in all directions at least to a limited angular extent, and means for restraining rotational movement of the ball about the longitudinal axis of the shaft.
The invention also provides cleansing apparatus for use in a vehicle cleaning system which includes a cleaning device, means for mounting at least the cleaning device to fixed structure, and drive means for causing the cleaning device to move about an axis, the mounting means permitting at least the cleaning device to move pivotally at least to a limited extent relatively to the fixed structure in at least one direction.
In one embodiment the drive means is located off-centre relative to the cleaning device and is connected to the cleaning device by means which imparts an eccentric motion to the cleaning device.
According to a different aspect of the invention there is provided cleansing apparatus for use in a vehicle cleaning system which includes a cleaning device, mounting means which supports the cleaning device from fixed structure, and drive means for imparting a cleaning motion to the cleaning device, the mounting means permitting the orientation of the cleaning device, relatively to the fixed structure, to vary or be varied.
In one form of the invention the drive means causes the cleaning device to rotate about an axis the inclination of which, relatively to the vertical, is variable.
In another form of the invention the drive means causes the cleaning device to move substantially over a conical surface of rotation.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is further described by way of example with reference to the accompanying drawings in which:
FIG. 1 is a side view of portion of cleansing apparatus according to one example of the invention,
FIG. 2 is a view of an upper section of the cleansing apparatus shown in FIG. 1, at right angles to the view shown in FIG. 1, along the line 2--2, and
FIGS. 3 and 4, and FIG. 5, schematically illustrate respective variations of the vertical.
DESCRIPTION OF PREFERRED EMBODIMENT
FIGS. 1 and 2 illustrate portion of cleansing apparatus 10 according to one example of the invention.
The cleansing apparatus 10 is mounted on a support 12 and includes a locating ring 14 fixed to an upper surface of the support, an upwardly facing concave socket 16 which is made from a plastics material with bearing qualities, registering holes 18 and 20 being formed through the socket and the support 12 respectively, a ball 22 which is formed with a lower surface complemental in shape to the concave socket and which is located in the socket, a shaft 24 which passes through a passage 26 extending through the ball and through the registering holes 18 and 20, bearing material 28 located in the passage and supporting the shaft, a sleeve 30 which surrounds the lower portion of the shaft 24 and which extends from the ball 22, the sleeve including bearing material 32 at its lower end which laterally supports the shaft, a flange 34 which is secured to the lower end of the shaft which protrudes from the sleeve, a bearing 36 in the form of a large plastic washer which is placed on the upper end of the shaft and which rides on an upper flat surface of the ball 22, a steel wear plate 38, also in the shape of a washer, which lies on top of the bearing and which is fixed to the shaft, a nut 40 which is threadedly engaged with a threaded upper end of the shaft which protrudes from the wear plate 38, two mounting and torsion bars 42 and 44 respectively which are fixed to opposed sides of the ball, see FIG. 2, and which extend upwardly, a floating plate 46 which is arranged horizontally and which is fixed to the upper ends of the bars 42 and 44 by means of nuts 48, the torque on the nuts 48 being such that the plate 46 is permitted to move slightly relatively to the bars 42 and 44, a hydraulic motor 50, powered via hydraulic hoses 52, which is mounted on an upper surface of the plate 46 and which has a downwardly depending shaft 54 engaged by means of a coupling 56 with the upper end of the shaft 24, a bracket 58 which is welded to an upper surface of the support 12 and which has a bolt 60 which is threadedly engaged with it, a protruding shank of the bolt being loosely engaged in an elongate slot 62 formed in a side of the ball 22, brackets 64 fixed to a lower side of the support 12, a clamp 66 which encircles the sleeve 30 at a location below the support 12, and a shock absorber 68 which is secured between the brackets 64 and the clamp 66. Although only one shock absorber 68 is shown in FIG. 1, in one particular embodiment of the invention at least two shock absorbers are employed.
The support 12 is at an elevated position and extends from suitable structure, not shown. The flange 34 is in practice engaged with an upper flange 70 of an elongate vertically aligned cylindrical cleaning brush 72 which includes a plurality of bristles 74 extending radially from a central shaft 76 which depends from the flange 70.
The apparatus shown in FIG. 1 is one of a plurality of similar arrangements which are erected at predetermined positions adjacent the path of travel of a vehicle which is to be cleansed. These aspects are determined in accordance with known criteria and do not pay a part in an understanding of the present invention. During the cleansing operation of a vehicle which is to be cleaned moves past the brush 72 and a side of the vehicle is brought into contact with the bristles 74 which are rotated via the shaft 24 and the hydraulic motor 50. A cleansing action is thereby applied to the respective surface of the vehicle.
It is apparent that the brush 72 is suspended from the support 12 by a joint which is in the nature of a ball and socket joint. Thus, despite the fact that the hydraulic motor 50, the ball 22, the shaft 24 and the sleeve 30 are rigidly connected to one another and to the brush 72, the assembly constituted thereby is pivotally movable relatively to the support 12 about a pivot point which is formed by the ball and socket and which is located at the support. This carries with it a number of important advantages.
In the first instance if the brush 72 is relatively long in the vertical direction, so as to accommodate high vehicles, and a low vehicle strikes a lower end of the brush the assembly can be pivotally deflected so that no significant bending moment is applied to the shafts 24 and 76. Secondly, and through similar reasoning, the brush 72 can follow practically any contours which may be encountered on a vehicle. It is to be borne in mind that the bristles 74 are flexible and consequently small irregularities can be accommodated. The fact that the shafts are pivotally displaceable in any direction, relatively to the vertical, about the joint comprising the ball 22 and the socket 16, permits the general contour of a vehicle side to be followed while the flexible bristles accommodate the finer irregularities.
A significant advantage arises from the fact that the shafts 24 and 76 are no longer caused to rotate about a rigidly maintained vertical axis, which is concentric with these shafts, but rather are free to rotate in a manner which is determined by any eccentricities or imbalances in the system. In this way practically all vibration is eliminated from the shafts and the brush when they rotate and this in turn implies that greater rotational speeds can be achieved. This means better and quicker cleaning action. With higher rotational speeds the bristles are subjected to greater centrifugal force and so effectively become stiffer. They therefore act as a buffer of increasing resilience and so are better able to absorb impact when a vehicle strikes them.
Should the bristles 74 become entangled with an obstacle on the vehicle which is being cleaned, for example any flexible element such as an air line, then although there is a strong probability that the flexible element will be broken by the forces which arise as a result of the entanglement the likelihood of damage being caused to the cleansing system itself is much reduced. Another advantage lies in the fact that the bearings 28 and 32 do not have to take up lateral forces generated by the shaft 24 and arising when a horizontal displacing force is exerted on the brush 72. It should be pointed out that in prior art devices which are rigidly mounted the bearings must be capable of withstanding lateral forces but these are of course substantially eliminated in the present invention because of the pivotal mounting provided by the ball and socket joint.
The invention has been described with reference to a ball and socket type mounting. The invention is however not confined in this respect for the ball and socket can be replaced by a flexible mount, for example made of resilient material such as rubber, which is fixed directly to the support 12 and from which the brush 72 hangs. Displacement of the axis of rotation of the brush, relatively to the support 12, thus takes place as the flexible mount is compressed, bent or otherwise distorted, during brush rotation.
In another variation of the invention shown schematically in FIGS. 3 and 4 the ball and socket joint is also dispensed with and a universal type coupling 80 is mounted to a fixed support 82 with the motor 50 hanging from the coupling. The coupling has a link 84 which can pivot in a first plane about a pin 86 which passes through a hole 88 in a bracket 90 on the underside of the support 82, while a similar bracket 92. fixed to the upper surface of the motor, can pivot in a second plane, displaced through 90° relatively to the first plane, about a pin 94 at the lower end of the link 84. The cleaning brush 74, not shown in these drawings, is suspended directly from the drive shaft 54 of the motor. Again the cleaning brush, the axis of rotation of which coincides with the drive shaft 54, is free to take up any orientation which may be dictated by forces which arise when the brush is rotated.
The cleaning brush can of course be replaced by any other cleaning device for example strips of cleaning material arranged in any suitable configuration and hanging from a suitable support. With this type of cleaning device, which is known per se in the art as a mitter, it is desirable to impart a "slapping" type movement to the strips. This may be achieved with the system shown schematically in FIG. 5 which illustrates a flexible rubber support 22A, which replaces the ball and socket and which is mounted on a support 100 which is inclined, but which may be horizontal as shown by a dotted line 100A, the motor 50 being located above the rubber support, and an eccentric linkage 102 which transfers rotational movement from the motor to a cleaning device 104 of the mitter type. In this case the cleaning device does not rotate about the shaft 106 on which it is mounted in the same way as the brush 72 of FIG. 1 but the shaft and the device 104, in unison, are caused to rotate in an eccentric manner about the rubber support 22A, more or less at a fixed orientation to the vertical, which passes substantially through the motor shaft 54, and so tracing out a substantially conical surface of rotation. The net effect is that the strips in the mitter are rotated, inclined to the vertical, and moved up and down, thereby acquiring a "slapping" action. This type of rotational pivotal movement is readily catered for by the rubber support, or in fact by the ball and socket joint and clearly could also be handled by a universal type coupling or any other resilient type mounting, in place of the rubber support, as has been discussed hereinbefore.
The shock absorber 68 may be used if the cleaning brush, or mitter, is subject to heavy impact loading. For most applications though the shock absorber is not required.
|
Cleansing apparatus for a vehicle washing system which includes a cylindrical brush and a motor for rotating the brush about a longitudinal axis. The brush is supported on a ball and socket joint which allows the orientation of the longitudinal axis to vary so that a "self balancing" system results which minimizes vibrations, permits higher brush rotational speeds, and which allows the brush to deflect when struck by a vehicle.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to foreign German patent application No. DE 102013005830.9, filed on Apr. 4, 2013, the disclosure of which is incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a slide rail for tensioning and guiding an endless drive member, said slide rail comprising at least one bore and a screw captively held in the bore. Furthermore, the invention also relates to a method for manufacturing a thin-walled slide rail for tensioning and guiding an endless drive member with at least one captively held screw for mounting said slide rail at an engine block, and a loss prevention device for captively mounting a screw at a thin-walled slide rail for tensioning and guiding an endless drive member.
BACKGROUND
[0003] Slide rails according to the invention are often mounted only when all other components of the respective drive have been already installed. In particular in the assembly of slide rails at timing chain drives, the engine case may be already closed during assembly. If in this case, not pre-assembled screws or screws not secured against loss are used, there is a risk of the screws falling into the engine when handled improperly. This increases the assembly efforts and thereby costs. It is therefore already known to provide a loss prevention device with such screws.
[0004] Such a loss prevention device for screws in a tensioning or guide rail is known from DE 11 2007 000 798 B4. It is described there that the tensioning or guide rail comprises an opening for receiving a retaining bolt and a lock projection is disposed in the opening. The retaining bolt comprises two lock indentations cooperating with the lock projection in the opening and permitting the captive retention of the retaining bolt in an assembly position and in a mounting position. In the assembly position, the lock projection is seated in the lock indentation of the retaining bolt facing the thread. When the retaining bolt is being mounted it is moved through the opening, the lock projection slips out of the first lock indentation and slides over the surface of the retaining bolt until the mounting position is reached and the lock projection comes into engagement with the second lock indentation.
[0005] The described loss prevention device may only be embodied in a tensioning rail having a certain thickness, so that the head of the retaining bolt with the two lock indentations may be received in the opening of the tensioning rail.
[0006] It is just in the automobile industry that a weight reduction of the individual components and the advantages involved are an important subject. It is therefore also known to employ thin-walled slide rails, in particular plate bending parts. With these thin-walled plate bending parts, the above mentioned loss prevention device cannot be realized.
SUMMARY OF THE INVENTION
[0007] It is therefore the object of the present invention to permit a captive mounting of screws in thin-walled slide rails for tensioning and guiding an endless drive member.
[0008] This object is achieved according to the invention by a sleeve being fixed to the bore and comprising engagement elements at its end facing the bore, i. e. the end facing the rail, where said engagement elements are engaged with the wall of the bore, and a stop collar lying against a stop face formed at the slide rail, and by lock elements being embodied in the sleeve which engage the thread of the screw and lock the screw at least in an assembly position, said slide rail being thin-walled.
[0009] Such a slide rail normally comprises a guide or a guide element in an upper region against which the endless drive member rests and is tensioned and/or guided. The width of said region of the tensioning rail therefore usually approximately corresponds to the width of the endless drive member. Starting from this guide area, the tensioning rail extends downwards to a region in which the at least one bore for receiving the screw and the screw itself are disposed. This region is clearly thinner than the guide region and therefore it is embodied thin-walled. The tensioning rail is embodied as a plate bending part and normally has a wall thickness within a range of 2 to 5 mm.
[0010] By a sleeve for receiving the screw being fixed to the bore, the bore is extended in the axial direction of the screw, so that the lock elements may be formed and a captive mounting of the screw in the bore is permitted. Thus, even in thin-walled slide rails, a loss prevention of the screw is realized and the assembly of the slide rail at the engine block facilitated.
[0011] Advantageously, it may be provided for the lock elements to be designed such that the screw may be released at least for a transfer to the assembly position. In the assembly position of the slide rail, the screw is disposed in the sleeve such that its end on the mounting side, that means the end which is introduced into the engine block for being mounted, does not, or only slightly, project over a mounting surface of the slide rail, that means the surface lying against the engine block when the slide rail is mounted. This permits to quickly bring the slide rail into an assembly position, so that the slide rail may be quickly and easily mounted to the engine block at the conveyor belt.
[0012] In still another advantageous embodiment, it may be provided for the lock elements to be designed such that the screw may be moved in both directions in the lock elements under the action of force. By the lock elements, the screw is thus captively held at the slide rail, while it is still possible to move the screw under the action of a force exceeding the forces usually occurring during transport, etc. Thereby, the screw may first be shifted towards the engine block, for example during assembly, so that a first centering of the screw in a corresponding bore in the engine block is permitted before the elements are subsequently finally screwed together.
[0013] It may furthermore also be provided for the sleeve to project to the outside starting from the slide rail and for the screw to lie with a screw head against the end of the sleeve facing away from the rail in a mounting position in which the slide rail is mounted to the engine block. The sleeve thus extends in the axial direction of the screw and supports the screw even in the assembly position, so that a tilt of the screw in the bore is prevented and thus assembly is facilitated. It is moreover thereby ensured that at least a part of the shaft of the screw is lying, in the mounting position, outside the engine block and the thread attached therein, so that a higher screwing force may be applied. Furthermore, in the mounting position of the slide rail, the screwing force is transmitted from the screw head to the sleeve and from there to the slide rail and the engine block respectively. In the mounting position, the engagement elements of the sleeve therefore do not have to transmit any force. Thereby, the engagement elements may have a relatively simple design.
[0014] To facilitate the mounting of the slide rail to the engine block, it may be provided for the engagement elements to be disposed in the bore and not project over the mounting side of the slide rail serving as a locating face at the engine block.
[0015] In yet a further embodiment, a lock component may be mounted inside the sleeve. This lock component forms lock elements. By a separate lock component being provided, the sleeve may have a relatively simple design. The lock is then realized by the separate component.
[0016] Advantageously, it may also be provided for the lock component or the sleeve to comprise a groove into which a projection at the sleeve or at the lock component engages. Thereby, the sleeve and lock component may be positively connected to each other; a simple manufacture of sleeve and lock component is ensured.
[0017] In a particularly advantageous embodiment, it may be provided for the lock component to be made of plastics and the sleeve to be made of a metallic material. This ensures that the sleeve is sufficiently stable for transmitting the screwing force in the mounting position of the screw or the slide rail. Since the lock component does not have to take up any forces in the mounting position but only serves for locking the screw before assembly, it may be made of plastics. This permits a simple shaping.
[0018] Yet another embodiment may provide for the lock elements at the sleeve to project outwardly at the end of the sleeve facing the rail. Thereby, the sleeve may be easily centered at the bore of the slide rail during mounting. A simple mounting is permitted.
[0019] It furthermore proved to be advantageous for the engagement between the engagement elements and the wall of the bore to be in line. This permits a simple fixing of the sleeve in the thin-walled slide rail.
[0020] Furthermore, the present invention also relates to the captive assembly of at least one screw in a bore of a body of a thin-walled slide rail for tensioning and guiding an endless drive member. The assembly method according to the invention comprises the following steps:
Inserting a sleeve comprising engagement elements into a bore in a body of the slide rail, so that the engagement elements are lying in the bore, applying a force onto the end of the sleeve facing away from the rail, simultaneously applying a counterforce onto the engagement elements arranged in the bore, so that the engagement elements are plastically deformed to the outside and engage the wall of the bore.
[0023] Thereby, a very simple and quick manufacture of a slide rail is permitted which ensures a loss prevention facility of the screw at the body of the slide rail.
[0024] Advantageously, the method may furthermore comprise the additional step of inserting a lock component and a screw locked in the lock component into the sleeve before applying the force and the counterforce, and of applying the force acting at the end of the sleeve facing away from the rail via the screw head. Therefore, all elements are connected to each other directly after the engagement elements of the sleeve have been calked in the bore of the slide rail. This permits a quick manufacture.
[0025] Furthermore, it may also be provided for the screw to be shifted into an assembly position after the sleeve has been fixed in the bore, in which position the screw does not or only slightly project over a mounting side of the slide rail. The slide rail is thus in a condition where it may be immediately fixed to the engine block. The assembly of the slide rail, which is typically done at the conveyor belt by a robot, is thus facilitated and accelerated.
[0026] Furthermore, the invention also relates to a loss prevention device for captively mounting a screw at a thin-walled slide rail for an endless drive member. Here, too, the object consists in permitting a simple and quick captive mounting of a screw at a slide rail.
[0027] According to the invention, it is provided to this end for the loss prevention device to comprise a sleeve with an end facing away from the rail at which a locating surface for a screw head of a screw is formed and which furthermore comprises an end facing the rail at which a stop collar for placing against a slide rail and engagement elements projecting over the stop collar in the longitudinal direction of the sleeve for engagement with a bore in the slide rail are embodied, and to furthermore comprise a lock component with lock elements protruding into the interior of the lock component for engagement with the thread of the screw, the lock component being mounted in the sleeve with a form-fit. In this manner, a simple loss prevention device for captively mounting a screw at a thin-walled slide rail is permitted.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] Below, the invention will be illustrated more in detail with reference to drawings. In the drawings:
[0029] FIG. 1 shows an exploded view of a screw with a loss prevention device consisting of a sleeve and a lock component,
[0030] FIG. 2 a shows the sleeve of FIG. 1 ,
[0031] FIG. 2 b shows a section through the sleeve of FIG. 2 a along line II-II,
[0032] FIG. 3 a shows a plan view onto the lock component of FIG. 1 ,
[0033] FIG. 3 b shows a section through the lock component of FIG. 3 a along line III-III,
[0034] FIG. 4 a shows a plan view onto the sleeve with the lock component inserted into it,
[0035] FIG. 4 b shows a section through the sleeve with the inserted lock component along intersection line V-V,
[0036] FIG. 4 c shows a section through the sleeve with the inserted lock component of FIG. 4 a along intersection line VI-VI,
[0037] FIG. 5 shows a perspective representation of a slide rail with two captively mounted screws,
[0038] FIG. 6 shows a side view of the slide rail, the region in which the screw is mounted being shown in a section,
[0039] FIG. 7 shows an enlarged representation of the bore of the slide rail with the screw captively mounted therein in a section, and
[0040] FIGS. 8 a to 8 f show a mounting of the sleeve with the mounting screw disposed therein and the lock component in a thin-walled slide rail.
DETAILED DESCRIPTION
[0041] FIG. 1 shows a screw 1 , a lock component 2 and a sleeve 3 in an exploded view. The screw 1 is a commercially available mounting screw with a shaft 4 on which a thread 5 is arranged and with a screw head 6 . In the represented case, the thread 5 extends up to the head 6 . The screw head 6 is provided with a hexagon rotary drive and has a stop plate 7 at the side facing the shaft 4 . The front end of the shaft, that means the end which is facing away from the screw head 6 , is free from threads; the thread only starts shortly behind it.
[0042] The lock component 2 has an essentially sleeve-like design and may be slipped onto the screw 1 . The lock component 2 comprises a ring 8 centrically disposed in the longitudinal direction L starting from which lock pins 9 extend in both directions, i. e. to the front and back. The lock pins 9 have a wider head area 10 on one side of the ring 8 and a narrower base area 11 on the opposite side. Adjacent lock pins are each disposed upside down relative to each other, so that next to the head 10 of one lock pin 9 , the base 11 of the adjacent lock pin 9 is arranged, etc.
[0043] The sleeve 3 has an end 12 facing the rail and an end 13 facing away from the rail. In a state where it is fixed to the slide rail, the end 12 facing the rail is lying against a body of the slide rail, while the end 13 facing away from the rail is facing away from the slide rail and functions as locating surface for the screw head 6 of the screw 1 . The end 12 facing the rail is provided with a stop collar 14 which is lying against a stop surface at the body of the slide rail in a mounting position of the sleeve. Furthermore, the sleeve 3 comprises engagement elements 15 which extend in the longitudinal direction to the outside starting from the stop collar 14 . At the end 13 facing away from the rail, a locating surface 16 is embodied at the sleeve 3 which functions as locating surface for the screw head 6 . Between the end 12 facing the rail and the end 13 facing away from the rail, a projection protruding inwards is provided in the sleeve which may cooperate with a corresponding taper of the lock component 2 .
[0044] FIG. 2 a shows an enlarged representation of the sleeve 3 of FIG. 1 . The sleeve 3 comprises the stop collar 14 in a lower region which functions to be placed against a stop surface of a slide rail. Starting from the stop collar 14 , four engagement elements 15 , each offset with respect to each other by 90° extend downwards. At the upper end of the sleeve 13 , that means at the end 13 facing away from the rail, a locating surface 16 for the screw head 6 of the mounting screw 1 is formed. Approximately centrically between the end 12 of the sleeve facing the rail and the end 13 of the sleeve facing away from the rail, an annular projection 17 protruding inwards is formed in the sleeve 3 .
[0045] FIG. 2 b shows a section through the sleeve 3 of FIG. 2 a along line II-II. One can see that the stop collar 14 is designed such that the lower end of the sleeve 3 is bent outwards in this region. The engagement elements 15 are punched out of the end of the sleeve 3 and are not bent outwardly with the stop collar 14 but are extended as elongation of the sleeve. The lower ends of the engagement elements 15 are slightly bent to the outside and have blades 18 at the outer side of the sleeve 3 . One can see that the stop collar 14 moreover comprises webs in the regions where the engagement elements 15 are cut out, so that a closed surface is formed and thus a sufficient stability of the sleeve 3 is achieved. The annular projection 17 protruding inwards is formed between the stop collar 14 and the locating surface 16 . This projection may be produced, for example, by rolling. The inner diameter D1 in the region of the annular projection 17 is smaller than the inner diameter D2 of the sleeve in the other regions, for example near the locating surface 16 . The lock component 2 may thus be fixed at the annular projection 17 .
[0046] FIG. 3 a shows a plan view onto the lock component 2 of FIG. 1 . The lock component 2 also has an essentially sleeve-like design and an outer diameter Da and an inner diameter Di. Six lock pins 9 are distributed one next to the other at the periphery of the lock component 2 . The design of the lock component can be seen more in detail in FIG. 3 b.
[0047] FIG. 3 b shows a section through the lock component 2 of FIG. 3 a along intersection line III-III. The lock component 2 comprises, in the longitudinal direction L approximately centrically, a ring 8 which connects the adjacent lock pins 9 with each other. The lock pins are only connected to each other by the ring 8 , and in the other regions, they are each separated from one another by an air gap 21 . The lock pins 9 each comprise one lock base 11 and one lock head 10 . The lock head 10 of the lock pins 9 is relatively wide and has a projection 19 facing outwards. Starting from the ring 8 , the lock head 10 is slightly bent to the outside. The width of the lock pins 9 decreases starting from the lock head 10 , therefore, the lock base 11 is narrower than the lock head 10 . Starting from the ring 8 , the lock bases 11 of the lock pins 9 are slightly inclined to the inside into the interior of the lock component 2 . The lock bases 11 each have a projection 20 protruding to the inside into the interior of the lock component 2 . Adjacent lock pins are each mirrored at the ring 8 , that means that next to the head 10 of one lock pin, the base 11 of the adjacent lock pin is disposed, and vice-versa.
[0048] FIG. 4 a shows the sleeve 3 with a lock component 2 inserted in it from the bottom. One can clearly see that the projections 20 at the lock bases 11 of the lock pins 9 project into the interior of the sleeve and lock component.
[0049] FIG. 4 b shows a section through the sleeve and the lock component of FIG. 4 a along line V-V. The lock component 2 is inserted in the sleeve 3 , so that the surrounding ring 8 of the lock component 2 is lying against the annular projection 17 of the sleeve 3 . Since the lock heads 10 of the lock pins project to the outside and the lock pins 9 are each disposed upside down relative to each other, a taper is formed in the lock component 2 and the lock component 2 is held inside the sleeve 3 by the lock pins 9 and the surrounding annular projection 17 of the sleeve 3 . Of course, it would also be possible to form the lock component and the sleeve such that a projection protruding to the outside is provided at the lock component and engages a groove in the wall in the sleeve and thus provides a mounting. The adjacent lock pins 9 are each separated by an air gap 21 , with the exception of the region of the surrounding ring 8 , so that an optimal resilience of the lock pin 9 is permitted.
[0050] FIG. 4 c shows a section through the sleeve 3 with the inserted lock component 2 along line VI-VI of FIG. 4 a . In this case, the section goes through two opposed lock pins 9 . One can see that these lock pins 9 are each disposed at the surrounding ring 8 to be mirrored with respect to each other. This means that the lock head 10 of the one lock pin is opposed by the lock base 11 of the other lock pin and vice-versa. The lock heads 10 are each lying against the inner wall of the sleeve 3 and in this manner lock the sleeve 3 with the lock component 2 via the annular projection 17 . The lock bases 11 protrude into the interior of the lock component and serve to lock the screw in the sleeve 3 . The inner diameter of the lock component 2 formed by the lock bases 11 therefore must be smaller than the outer diameter of the thread of the screw 1 . The projections 20 at the lock bases 11 then engage the thread of the screw 1 . Since adjacent lock pins 9 are arranged such that one lock base 11 each comes to lie next to the lock head 10 of the adjacent lock pin 9 , the screw is retained in regions spaced apart with respect to each other in the longitudinal direction. This reduces the risk of the screw tilting before being assembled. The lock pins are resilient. The projections 20 of the lock bases 11 have rounded contours. If now a sufficiently high force is exerted onto the screws, the projections 20 of the lock bases 11 are bent outwards against the spring force of the lock pins 9 and release the screw, or unlock it. The screw may then be moved into both directions in the sleeve and the lock component.
[0051] FIG. 5 shows a perspective representation of a slide rail 22 with two captively held screws 1 . The slide rail 22 comprises a body 23 at the upper region of which a slideway lining 24 for tensioning and guiding an endless drive member is disposed. The width of the slideway lining 24 approximately corresponds to the width of the endless drive member. The body 23 of the slide rail 22 is formed as plate bending part and therefore has a thickness of only a few millimeters, preferably 2 to 5 mm. The width b of the body 23 is small compared to the width B of the slideway lining 24 . So, this is a thin-walled slide rail 22 . At the end of the body 23 facing away from the slideway lining 24 , the slide rail 22 has two captively held screws 1 . For this, two bores 25 are provided in the body 23 of the slide rail 22 , in which one sleeve 3 each is mounted with the lock component 2 disposed at it. The screws 1 are held in the lock components 2 .
[0052] FIG. 6 shows a side view of the slide rail 22 , the slide rail being shown in a section in the lower region, that means in the region where the screws 1 are captively held. The slide rail 22 comprises a body 23 and a slideway lining 24 . In the represented case, the slideway lining 24 is embodied separately and connected to the body 23 . However, the slideway lining could also be formed integrally with the body. The width B of the sliding area 24 is clearly greater than the width b of the body 23 of the slide rail 22 . Therefore the slide rail 22 is thin-walled. Preferably, the body 23 of the slide rail 22 is embodied as a plate bending part with a wall thickness of only a few millimeters. At the end of the body 23 facing away from the slideway area 24 , two bores 25 are formed. In these bores 25 , one sleeve 3 each is inserted and connected with the body 23 of the slide rail via engagement elements 15 . The lock component 2 is disposed in the sleeve 3 and locks the screw 1 in the sleeve 2 and thus at the body 23 of the slide rail 22 .
[0053] FIG. 7 shows an enlarged representation of the region of the body 23 of the slide rail 22 in which the screw 1 is captively held. The sleeve 3 is arranged in the bore 25 in the body 23 of the slide rail 22 such that the stop collar 14 of the sleeve 3 is lying against the outer side of the body 23 of the slide rail. The engagement elements 15 protrude into the bore 25 , and the blades 18 of the engagement elements 15 engage the wall of the bore 25 and tightly hold the sleeve 3 at the body 23 of the slide rail 22 . The lock component 2 is inserted in the sleeve 3 and the lock bases 11 of the lock component 2 engage the thread 5 of the screw 1 . Thus, the screw 1 is locked. The lock pins 9 are resilient such that the screw 1 may be moved in the sleeve 3 in both directions if a sufficiently high force is applied. This force must be greater than the forces usually occurring, for example, during transport. The projections 20 of the lock bases 11 are rounded, so that, when the screw is moved, no excessive forces act on the thread of the screw and the projections of the lock bases, and thus the thread and the lock bases are not damaged.
[0054] Preferably, the sleeve 3 is made of a metallic material while the lock component 2 is made of a plastic material.
[0055] FIGS. 8 a to 8 f show the steps of mounting the sleeve 3 and the lock component 2 and the screw 1 in the body 23 of a slide rail. As can be seen in FIG. 8 a , first the sleeve 3 with the lock component 2 disposed in it and the screw 1 inserted in the lock component 2 is inserted into the bore 25 of the body 23 until the stop collar 14 of the sleeve 3 is lying against the outer side of the body 23 . The engagement elements 15 then lie against or near the wall of the bore 25 . Subsequently, a device 26 is placed against the screw head 6 of the screw 1 . In the lower region, that means in the region of the shaft of the screw 1 , a counter-device 27 is applied which acts on the engagement elements 15 in the sleeve 3 (see FIG. 8 b ). As can be seen in FIG. 8 c , now a force F 1 and a counterforce F 2 are applied by the device 26 and the counter-device 27 and act on the sleeve 3 . Since the screw 1 is already arranged in the sleeve 3 , the force F 1 is applied onto the screw head 6 of the screw 1 and introduced via the screw head 6 into the sleeve 3 . This force F 1 , together with the counterforce F 2 , cause the engagement elements 15 of the sleeve 2 to be bent to the outside and the blades 18 of the engagement elements 15 to penetrate the wall of the bore 25 and interlock the sleeve 3 there. So, the sleeve 3 is calked with the body 23 of the slide rail 22 . This can be seen in FIG. 8 d . Then, the device 26 is removed (this is shown in FIG. 8 e ). A device 28 exerts a force onto the shaft of the screw 1 and the screw 1 is pushed outwards until it lies in an assembly position and the tip of the screw 1 only slightly protrudes over the slide rail 22 . So, the slide rail 22 may be immediately mounted to the engine block at the belt without having to adjust the screw 1 .
[0056] As soon as the slide rail 22 is screwed to the engine block, the force for holding is transmitted from the screw head 6 to the sleeve 3 and via the stop collar 14 to the body 23 of the slide rail. In the mounted state of the slide rail, that means in a state where the slide rail 22 is mounted at the engine block, the engagement elements 15 do not have to absorb or transmit any more forces. The lock component 2 neither has to take up any forces. The lock pins 9 of the lock component 2 therefore only serve for locking the screw before the assembly of the slide rail. Therefore, it is no problem to produce the lock component 2 of plastics, so that a simple manufacture and shaping is possible.
|
In the field of a slide rail for tensioning and guiding an endless drive member, comprising at least one bore and a screw captively held in the bore, permitting the captive mounting of screws even in thin-walled slide rails is provided. A sleeve is mounted in the bore and the sleeve comprises engagement elements at its end facing the rail, said engagement elements being engaged with the wall of the bore, and a stop collar lying against a stop surface formed at the slide rail, and lock elements are embodied in the sleeve which engage the thread of the screw and lock the screw at least in an assembly position, wherein said slide rail is thin-walled. Furthermore, an assembly method is provided for manufacturing the slide rail with a captively held screw and to the loss prevention device per se.
| 8
|
BACKGROUND OF THE INVENTION
This invention relates generally to fiber-resin composite pultrusion methods and products. More particularly, the present invention relates to a composite rod which has a fluid-tight hollow interior space that may be filled with a liquid, such as water or oil, at a job site and subsequently sealed to greatly increase the strength of the rod.
In manufacturing composite rods, a variety of competing design considerations are at stake. On the one hand it is desirable to have a rod that is as light as possible to provide for easy transport and use by consumers. On the other hand the rod must have the structural integrity to withstand the variety of stresses that will be placed on it.
The basic technique for running filaments through a resin bath and then through an elongated heated die tube .to produce a cured composite rod of the same shape as the die tube has been known for some time. See, for example, U.S. Pat. Nos. 2,948,649 and 3,556,888. This method, however, produces a solid extruded product which is unacceptably heavy and/or too rigid for many applications.
The weight problem can be alleviated by means of a process to extrude hollow tubes utilizing a die tube with the center filled, leaving an annular cross-section through which the resin coated fibers are pulled. This weight reduction is achieved, however, at the cost of significantly reduced bending or flexural strength in comparison with a solid rod, resulting in a rod which would not be suitable for use in certain high stress applications. Further, to increase interlaminar strength of the tube forming fibers, a substantial percentage of fibers running other than in a longitudinal direction have been thought to be required.
The bending strength of composite rods can be improved by producing fiber-resin rods which are substantially hollow or lightweight throughout a major portion of their length, but reinforced at areas of expected high stresses during use. Such improved rods and related methods are shown, in connection with tool handles, in U.S. Pat. No. 4,570,988, the contents of which are incorporated herein by reference. These composite tool handles have further been improved by the introduction of one or more reinforcing beads of fiber-resin material extending the length of the load bearing rod, as shown in U.S. Pat. No. 4,605,254, the contents of which are incorporated herein by reference.
Such composite rods have further been improved by introducing corrugations in the outer surface of the fiber-resin jacket during the pultrusion process. More particularly, one or more external mold members may be channeled into the pultrusion die tube in the space between the die tube and the resin coated fibers to shape the outer surface of the jacket. Similar processes are utilized to modify the internal configuration of the fiber-resin jacket as well. See, for example, U.S. Pat. No. 5,421,931, the contents of which are incorporated herein by reference.
There remain applications in which high strength rods are utilized, but wherein composite rods have heretofore been thought to be unacceptably expensive or lacking the required strength characteristics to be utilized in such applications. One such application is in connection with trench shields. Trench shields are used in all sorts of construction in which a trench must be dug, for example, in connection with laying large pipe for sewers, conduit or building foundations. Trench shields come in a wide assortment of sizes to accommodate trenches typically ranging in size from twenty four inches in width to one hundred eight inches in width.
Trench shield side walls or panels of appropriate size and strength for the depth of the trench are placed on either side of the trench to preclude cave-ins, both for the safety of the workers and to preclude the necessity of having to re-dig the trench if the sides cave in. These panels are held in position by cross bars, or spreader bars, of appropriate length and strength. Hardware, such as spreader bar support brackets, is affixed to each end of the spreader bar to provide a mating attachment between a respective end of the spreader bar and the adjacent portion of the side wall or panel.
At the present time virtually all spreader bars are made of heavy walled steel tubing. The principal shortcoming of utilizing such heavy walled steel tubing is the weight thereof. The heavy weight of such steel tubing is a negative as it substantially increases the cost of shipping and, as the spreader bars get larger and longer, the workmen cannot handle it and mount it in place by hand, but must use a piece of equipment such as a back hoe, crane or some other piece of equipment. This is slow, time consuming and expensive for the contractor who would normally prefer to have an adequately strong spreader bar which could be handled by one man in most instances.
Spreader bars must have the compressive strength to resist bending or breaking from the loads created by the side panels holding back the walls of the trench. They must also be rugged and stout enough to take the occasional abuse of the rough and tumble crew and its equipment. The inherent strength, weight, toughness and non-corrosive characteristics of fiberglass composite rod make it an ideal material for this application. Certain design problems present themselves, however, particularly if a fiberglass tube is used. The resistance of a fiberglass tube to having its circular hoop integrity damaged is much greater than steel as it is not nearly as stiff. The flexural modulus of a fiberglass tube is in the order of magnitude of five to six million, while steel is in excess of fifteen million. Additionally, the resistance to dinging and abuse of a fiberglass tube is lower than that of steel.
Accordingly, there is a need for an alternative to heavy walled steel tubing in applications such as for use in trench shields, which incorporate the advantages of fiberglass composite rods and yet maintain the structural and strength characteristic of such heavy walled steel tubing. Fiberglass composite rods utilized in such high strength applications must have improved resistance to dinging, and means for improving their circular hoop integrity to approximate that of steel tubing. Moreover, such high strength fiberglass composite rod is needed which is relatively lightweight for transportation, storage and handling at the job site. The present invention fulfills these needs and provides other related advantages.
SUMMARY OF THE INVENTION
The present invention resides in a composite rod assembly manufactured in a pultrusion manufacturing process to include a fluid-tight hollow interior space that may be selectively filled with a liquid to transform the rod assembly into an hydraulic solid rod. A process for manufacturing such a composite rod assembly includes the steps of alternately introducing a first reinforced core, an elongated hollow tube and a second reinforced core into a pultrusion die tube, surrounding the reinforced cores and the hollow tube with resin-coated fibers, pulling the reinforced cores and the hollow tube through the pultrusion die tube while keeping the reinforced cores and the hollow tube surrounded by the resin-coated fibers, and curing the resin-coated fibers around the reinforced cores and the hollow tube to form a fiber-resin jacket. The hollow interior space is defined as the volume within the hollow tube between the reinforced cores. Means also provided for accessing the hollow interior space in order to introduce a liquid therein or to drain a liquid therefrom, and for re-sealing the hollow interior space thereafter. Utilizing the foregoing basic pultrusion manufacturing process, a composite rod assembly is formed which includes a elongated pultruded jacket of fiber-resin material which has a first end and second end. The pair of reinforced cores are disposed within the fiber-resin jacket at the first and second ends thereof such that they form a fluid-tight seal with the fiber-resin jacket.
In a preferred form of the invention, a molded protective sleeve encases the fiber-resin jacket. This molded protective sleeve provides means for protecting the jacket against cutting and chipping-type damage. At least one of the reinforced cores comprises a tubular, interiorly threaded insert about which the fiber-resin jacket is molded, and an end plug having a threaded shaft that is received within the threaded insert. The end plug includes a head flange. The reinforced core further includes an O-ring disposed between the head flange and a facing end of the threaded insert in order to provide a fluid seal therebetween. The threaded insert and the end plug provide the hollow interior space accessing means in that removal of the end plug from the insert permits access to the hollow interior space, and replacement of the end plug into the threaded insert re-seals the hollow interior space.
In another preferred form of the invention, the composite rod assembly includes a molded protective cap which encases each end of the fiber-resin jacket. Like the protective sleeve, the protective cap provides means for protecting the jacket against cutting and chipping-type damage. In this embodiment, at least one of the reinforced cores comprises a substantially solid fiber-resin insert about which the fiber-resin jacket is molded during the pultrusion manufacturing process. The hollow interior space accessing means comprises an access aperture through a portion of the fiber-resin jacket. The rod assembly further includes a threaded insert disposed adjacent to the access aperture and aligned therewith for receiving a threaded shaft of a sealing plug.
In both illustrated embodiments, the steps of removing the end plug or sealing plug from the respective threaded insert, introducing a liquid through the threaded insert into the hollow interior space until said space is completely filled, and replacing the end plug or sealing plug into the respective threaded insert to reseal the hollow interior space, transforms the rod assembly into an hydraulic solid rod.
Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate the invention. In such drawings:
FIG. 1 is fragmented perspective view of a trench shield in use, utilizing a pair of spreader bars embodying the present invention;
FIG. 2 is an enlarged fragmented exploded perspective view of one end of a spreader bar illustrated in FIG. 1;
FIG. 3 is an enlarged elevational view of an end of the spreader bar illustrated in FIG. 2;
FIG. 4 is an enlarged, fragmented and partially sectional view of the spreader bar of FIGS. 13, taken generally along the line 4--4 of FIG. 2;
FIG. 5A is a schematic vertical sectional view of the spreader bar of FIGS. 1-4, illustrating the step of filling a hollow interior of the spreader bar with water.
FIG. 5B is a vertical sectional view of a spreader bar similar to that shown in FIG. 5A, illustrating the step of replacing an end plug once the hollow interior of the spreader bar has been filled with water;
FIG. 5C illustrates the step of placing the water-filled spreader between two trench shield side walls; and
FIG. 6 is an enlarged fragmented sectional view of another embodiment of a spreader bar embodying the present invention, wherein threaded access apertures to the hollow interior of the spreader bar are provided through a side wall rather than through the ends thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in the drawings for purposes of illustration, the present invention is concerned with an hydraulic solid rod, generally designated in the accompanying drawings by the reference number 10. The hydraulic solid rod 10 may be utilized as, for example, a spreader bar in a trench shield 12. Such trench shields 12 normally include a plurality of spreader bars 10 fixed at opposite ends to trench shield side walls 14 by means of support brackets 16. The trench shield side walls 14 are typically placed below a ground surface 18 adjacent to earthen walls 20 of a trench, to prevent their collapse (see FIG. 1).
In accordance with the present invention, the spreader bar 10 is manufactured, at least in part, by a pultrusion process and includes alternating sections of a heavy duty, reinforced core 22 and hollow plastic tubing 24 surrounded by a cured fiber-resin jacket 26. The reinforced core 22 is located at each end of the spreader bar 10 and is configured to provide a fluid-tight seal between the fiber-resin jacket 26 and a hollow interior 28 of the spreader bar 10. The hollow plastic tubing 24 extends through the remainder of the spreader bar (hydraulic solid rod) 10 to minimize the weight of the spreader bar and also to define the hollow interior 28. A protective sleeve 30 may be molded over the exterior of the fiber-resin jacket 26 to improve the spreader bar's resistance to cutting and chipping-type damage. Alternatively, a protective cap 32 may be molded over the ends of the spreader bar 10 for the same purpose.
To manufacture the spreader bar 10, a fiber material is drawn off a series of spools or bails and then passed through a resin bath and through a carding disk into a pultrusion die tube where the fibers surround the alternating sections of reinforced core 22 and the hollow plastic tubing 24. The resin coated fibers are pulled through the die tube and are heated and cured about the cores 22 and 24 by a conventional conduction heater or a microwave heating element which surrounds the die tube. The cured rod (or spreader bar 10), consisting of the fiber-resin jacket 26 surrounding the core sections 22 and 24, is pulled out of the die tube by tractor-type pullers and cut into the desired length by a conventional cutting device. Such a pultrusion manufacturing process is well known in the art. See, for example, U.S. Pat. No. 4,570,988.
In one preferred embodiment of the spreader bar shown in FIGS. 2-5(A, B and C), the reinforced core 22 comprises means for gaining access to the hollow interior 28 through an end of the spreader bar 10. In this regard, the reinforced core 22 comprises an interiorly threaded metal insert 34 which is placed in abutting relation with the hollow plastic tubing 24 and spaced so as to be positioned at each end of the resultant spreader bar 10. The metal insert 34 is surrounded by the resin-coated fibers during the pultrusion manufacturing process so that the fiber-resin jacket 26 forms a bond with an exterior surface of the metal insert 34. An end plug 36 includes a threaded shaft 38 that may be screwed into the insert 34. The end plug 36 further includes a head flange 40 which is capable of compressing an O-ring between the head flange and an exposed end of the insert 34 for purposes of insuring a fluid-tight seal between the end plug 36 and the threaded metal insert 34. The end plug 36 also includes an exterior recess 44 in which is positioned a hex head 46 to facilitate turning of the end plug 36 by means of, for example, a socket wrench.
The fiber-resin jacket 26 is encased by a PVC sleeve which forms the protective sleeve 30 mentioned above. This particular arrangement results in a spreader bar 10 which is relatively lightweight (in comparison with metal tubes), and which can thus be transported and handled conveniently by a lone workman.
In order to increase the strength of the spreader bar 10 at the job site for high-strength applications such as use as spreader bar 10 in a trench shield 12, one of the end plugs 36 is removed to expose the hollow interior 28. The hollow interior 28 is filled with a liquid, normally water (see FIG. 5A), and when the hollow interior 28 is completely filled with the selected liquid, the end plug 36 is replaced (see FIG. 5B). The resultant hydraulic solid rod 10 comprises a hollow bar filled with a liquid and corked. The hydraulic principle acts as though it were a solid throughout inasmuch as pressure created upon the incompressible fluid is transmitted in all directions without diminishing. This precludes the tube from having its circular integrity compromised. Thus, with the hollow interior 28 filled with the liquid 48, the hydraulic solid rod 10 is ready to be utilized as a spreader bar (see FIG. 5C).
In another preferred embodiment of the invention shown in FIG. 6, the reinforced core 22 comprises a solid fiber-resin insert plug 50 similar to the reinforcing core sections of U.S. Pat. No. 4,570,988. The fiber-resin insert plugs 50 are drawn through the pultrusion die tube with the hollow plastic tubing 24 such that as the resin-coated fibers cured to form the fiber-resin jacket 26, a fluid-tight seal is formed between the fiber-resin jacket 26 and insert plugs 50 as well as the hollow plastic tubing 24. In this embodiment, however, a metal threaded insert 52 is interposed between adjacent ends of the fiber-resin insert plug 50 and a hollow plastic tubing 24. A plug (not shown) may be threaded into the metal threaded insert 52, which has an exterior surface that will abut the interior of the pultrusion die tube. The fiber-resin jacket 26 is then molded to provide an access aperture 54 therethrough an alignment with an aperture of the metal threaded insert 52. This access aperture 54, two of which are provided, allows liquid to be inserted into the hollow interior 28 or withdrawn therefrom for purposes of filling or draining the spreader bar 10 as desired. The access aperture 54 may be sealed by a plug 56 that includes a threaded shaft 58 received into the insert 52, and a hex head 60. An O-ring 62 is provided between the hex head 60 and adjoining exterior surface of the fiber-resin jacket 26 to ensure a fluid-tight seal. When the plug 56 is removed from the access aperture 54, a filler hose 64 having a threaded coupling 66 may be utilized to fill the hollow interior 28 of the spreader bar 10 with liquid under pressure.
In this particular embodiment, a glass-filled nylon protective cap 32 is molded over each end of the solid rod 10. This protective cap 32 provides the desired resistance to dinging, cutting and chipping-type damage to the solid rod, especially as the ends of the hydraulic solid rod/spreader bar 10 are received within support brackets 16.
From the foregoing it will be appreciated that an un-filled hydraulic solid rod 10 constructed in accordance with the present invention will have a weight approximately twenty-five to thirty percent of a comparable steel bar. Thus, the unfilled hydraulic solid rod 10 will be easily handled by one or perhaps two men for installation on the job site. On reaching the job site the workmen need only to fill the hollow interior 28 with a liquid to increase the strength of the hydraulic solid rod 10. Normally water is sufficient, but in applications where the rod 10 will be permanent or semipermanent, another liquid could be substituted for the water, such as oil.
When the contractor is ready to remove the rod 10 from the job site, such as when the trench shield 12 is to be dismantled, the liquid 48 within the hollow interior 28 is drained so that the weight of the rod 10 is greatly reduced for storage and/or trans-shipment. In the case of the embodiment of the solid rod 10 including access apertures 54 through a wall of the fiber-resin jacket 26, it is preferred that the rod 10 be rotated so that the access apertures 54 point downwardly. At the end of construction the water can be drained quite easily in this configuration.
By molding the reinforced core 22 continuously with the hollow plastic tubing 24 in such a manner that the fiber-resin jacket 26 forms a seal between the tubing 24 and the core 22, a fluid-tight interior 28 is achieved in a highly efficient manner designed to reduce costs to a minimum.
Although several embodiments of the invention have been described in detail for purposes of illustration, various modifications may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited, except as by the appended claims.
|
A hollow composite rod manufactured in a pultrusion manufacturing process includes a hollow interior space that may be filled with a liquid, such as water or oil, and subsequently sealed to greatly increase the strength of a resultant rod assembly. The composite rod includes a high strength, pultruded fiber-resin jacket that, at each end, is molded about a reinforced insert to create a fluid-tight seal therebetween. Threaded access apertures are provided through either the reinforced inserts or the jacket itself, to permit the filling or draining of fluid relative to the hollow interior space. Reinforcing sleeves or caps may be molded over a portion of the jacket's exterior to improve the composite rod's resistance to cutting and chipping-type damage.
| 8
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to mechanism for controlling needle bight in a sewing machine.
2. Description of the Prior Art
Needle bight controlling mechanisms including cams which can selectively be brought into play to cause a needle to be moved in zig-zag fashion according to the design of the cams are well known. Such mechanisms, however, have generally been unduly complex and have failed to provide trouble free operation over long periods of time. Furthermore such mechanisms have been difficult to assemble, and in particular could not be easily assembled with relatively few parts into a module for subsequent insertion in the machine. It is a prime object of the present invention to provide an improved needle bight control mechanism which requires few parts, which can be readily and economically manufactured as a sub-assembly apart from the machine and which will operate reliably over long periods of time.
SUMMARY OF THE INVENTION
In accordance with the invention there is provided a needle bight control mechanism including a rotable cam stack, a cam follower for each of the cams of the cam stack mounted for pivotal and translational movement, a pivoted bracket which is part of needle bight actuating linkage means and which is subject to actuation of the cam followers, a drum having an interposer thereon for each cam follower, means for turning the drum to selectively dispose a follower to interact with its associated cam and actuate the pivoted bracket, and indexing means operably associated with the interposer carrying drum, the indexing means being adapted to embrace and hold the cams of the cam stack and cam followers in alignment. The entire mechanism is mounted in a supporting structure which is securable with just a few screws in the machine.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of a sewing machine from which a portion of the front cover has been broken away to show the needle bight control mechanism of the invention;
FIG. 2 is a perspective partially exploded view showing the needle bight control mechanism of the invention;
FIG. 3 is a front elevational view, partially in section, of the needle bight control mechanism showing a cam follower on a raised surface of an actuating cam; and
FIG. 4 is a fragmentary front elevational view of the needle bight control mechanism showing the cam follower in a trough of the actuating cam.
FIG. 5 is a sectional view taken on plane of the line 5--5 of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 of the drawings, a sewing machine 10 is shown as including a bed 12, a standard 14 rising from the bed and a bracket arm 16 overhanging the bed. A needle bar 18 is supported in a gate 20 for endwise reciprocation by an arm shaft 22 acting through a crank 24, drive link 26 and needle bar attached collar 28. As shown the gate 20 is mounted at its upper end for pivotal motion on a shaft 31 located in frame 32 such that zig-zag motion is imparted to a needle 33 when actuating forces are exerted on the gate by a needle bight control link 30 and return spring 32.
Mechanism is provided in accordance with the invention for controlling needle bight, that is the amplitude of needle zig-zag movements. Such mechanism, which is best shown in FIGS. 2, 3 and 4, includes a plurality of side-by-side rotatable cams 34, a follower 36 for each of the cams, an interposer 38 for each of the cam followers, a bracket 40 wherein the cam followers are assembled, and an indexing pawl 42 which embraces the cams, the cam followers and interposers.
The cams 34 are securedly screws 44 to the flange 46 of a sleeve 48 having a plastic gear 50 molded into a fixed position thereon. The sleeve is rotatably mounted on an eccentric portion 51 of a shaft 52 which is affixed in frame 54 by a screw 56; and when gear 50 is caused to rotate, rotation is imparted to sleeve 48 and the cams 34. Axial movement of the cams 34, sleeve 48 and gear 50 is restrained by a boss 58 of the frame 54 located opposite one end of sleeve 48, and by a screw 60 which is integral with shaft 52 and has a shoulder 62 opposite the other end of the sleeve.
The cam followers 36 are mounted on a pin 64 which is affixed in frame 54 by a screw 66. Pin 64 extends through a slot 67 in each of the cam followers and the cam followers can both pivot and slide on the pin. The pin also extends through bracket 40 and the bracket may pivot on the pin. As shown, the cam followers 36 are located on pin 64 between sides 68 and 70 of bracket 40. As noted hereinbefore, there is an interposer 38 for each cam follower 36. Such interposers are located on a drum 72 which is turnable on an eccentric portion 73 of a shaft 74 that is secured to frame 54 by screw 78.
Pawl 42 includes side walls 80 and 82 which embrace the axially fixed cams, the cam followers and the interposer drum to maintain each of the cam followers in alignment with a particular cam and maintain the interposer drum 72 in a position on shaft 74 wherein each of the interposers is aligned with a particular cam follower. The pawl 42 is pivotally mounted on a pin 84 affixed in the frame 54 and is biased about the pin by a spring 86 against the interposer drum. The pawl is formed at 88 to engage adjacent interposers 38 and define indexed positions for the drum wherein a selected interposer is disposed opposite its associated cam follower for engagement by the cam follower.
The entire needle bight control mechanism including a plate 90 secured by screw 92 to frame 54, a control knob 94 for turninng interposer drum 72, and a control knob 95 for use as hereinafter described can be readily assemble into a subassembly apart from the sewing machine casing and thereafter secured in place as with screws 96, 98, 100, 102 and a bracket 104 extending between the screws 100 and 102. Before the subassembly is affixed in the machine various adjustments can be made in the needle bight control mechanism as required for proper operation. Such adjustments include an adjustment in the position of the interposer drum 72 relative to the cam follower and an adjustment in the position of gear 50 as required for proper engagement with a worm 106 on the arm shaft 22 of the machine. The adjustment in the position of the interposer drum is accomplished by turning shaft 72 as with a screw driver in slot 108 to selectively position eccentric portion 73 of the shaft before the shaft is finally affixed in frame 64 with screw 78. The adjustment in the position by gear 50 is accomplished by turning shaft 52 with a screwdriver in slot 110 of screw 60 to selectively position eccentric portion 112 of the shaft 52 before such shaft is finally affixed in frame 54 with screw 56.
Bracket 40 of the needle bight control mechanism connects through a link 112 and needle bight control link 30 with needle bar gate 20. An operator selects an interposer 38 for engagement by a particular cam follower 36 with control knob 94, and spring 33 acting through links 30 and 112 urges bracket 40 about pin 64 to thereby cause a fixed pin 114 in the bracket to urge the cam followers about the pin 64 to positions wherein the interposer selected with the control knob 94 is engaged at cam surface 116 by the aligned cam follower 36 and one end of such cam follower is in contact with its associated cam 34. Gear 50 is rotated continuously by engaging worm 118 on arm shaft 22 during operation of the machine and the cams 34 rotate with the gear. The cam follower in engagement with the selected interposer is actuated by the high spots on the associated rotating cam and pivots about pin 64 causing surface 116 thereon to act against surface 120 of the selected interposer, and cam follower 122 to act against pin 114 in bracket 40. The bracket is pivoted about pin 64 by the cam follower and motion is imparted to the needle bar gate 20 through links 112 and 30 causing the needle bar gate to move to the left as viewed in FIG. 1. When the cam follower moves off a high spot on the engaged cam the gate 20 is moved to the right by the action of spring 33 which also acts through links 30 and 112, and bracket 40 to keep the cam follower in contact with its associated cam. All of the cam followers 36 other than the cam follower opposite the selected interposer float on pin 64 during rotation of cams 34 and exert no effect on the motion of bracket 40 and the needle bar gate 20.
As shown link 112 terminates in a slot 124 formed between side pieces 126 and 128 which are affixed to bracket 40 with a strap 130. The end 132 of link 112 in slot 124 rides on an edge 134 of the bracket. Link end 132 may be positioned along the edge 134 with control knob 95 which is affixed to a pin 135 slidable in a slot 136 is link 112, and in this way the amplitude of the movement of the needle bar gate 20 and thereby the width of the needle bight obtained in response to the interaction of a cam follower and associated cam following the selection of a particular interposer may be predetermined by an operator. The closer link end 132 is located to the top of edge 134 the greater the width of the needle bight obtained, and when link end 132 is at the bottom end of curved edge 134 in line with the axis of pin 64, straight stitches results.
As shown links 30 and 112 are affixed to one another by bolts 138 and 140, and the nuts 142 and 144. The bolts extend through slots in link 112 (not shown) to permit the links 30 and 112 to be slidably adjusted relative to each other at the time the machine is manufactured and a straight stitch location to be thereby established for the needle 33 with link end 132 in line with the axis of pin 64. Edge 134 is formed with a slight curvature which maintains the straight stitch location of the needle as a median postion regardless of the width of needle bight selected by an operator with knob 95.
Although only a particular preferred embodiment of the invention has been shown and described by way of illustration, various modifications will occur to those skilled in the art, and it is, therefore to be understood that it is intended herein to cover all such modifications as fall within the true spirit and scope of the invention.
|
A sewing machine is provided with a unique needle bight control module including a rotatable cam stack, a cam follower for each of the cams of the cam stack, and a drum with interposers thereon selectively disposable against the cam followers for causing needle bight controlling linkage means to be moved during rotation of the cam stack according to the design of the cam which is associated with the cam follower selectively engaged by the interposer. Indexing means embraces and holds the cams, interposers and cam followers in alignment.
| 3
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the fabrication of multilayer substrates, and more particularly pertains to the incorporation therein of non-destructive test structures utilized to provide visual and electrical test data to facilitate the ascertainment and assessment of potential electrical interface failures. Furthermore, the invention is directed to the provision of embedded structures in a multilayer substrate, such as employed in chip carrier packaging, so as to facilitate electrical testing for via to via alignment and interface layer alignment, and to enable the testing of conductive interface electrical integrity of multilayer electrical devices.
The invention is further directed to the provision of a novel method for the non-destructive testing of electrical integrity in multilayer devices and substrates, as well as implementing electrical testing for via to via alignment and interface layer alignment in multilayer substrates and electrical semiconductor devices, such as are employed in chip carrier packaging.
During the process for the building-up or fabricating of multilayer ceramic substrates there are produced critical electrical interfaces which exist on each layer and also between adjacent or superimposed layers. These interfaces are typically formed on dielectric layers known as greensheets and constitute vias and electrically conductive patterned features such as lines or mesh planes, each of which may have a capture pad or cap provided on their ends in order to increase the contact area with their respective adjoining electrically conductive circuit element. The alignment of each of these interfaces is extremely critical, especially inasmuch as ever narrower line widths and smaller vias are used to be able to increase the wiring density of an electrical device. Also, at high frequencies above 10 GHz, discontinuities in conductor surface features can degrade the electrical performance of signals. Misaligned conductor interfaces can act as such discontinuities and limit the high frequency performance of multilayer devices. Typical specifications permit no more than one-half the diameter of a via as the misregistration or offset between adjacent layers at any location within a laminate. After adjacent layers are laminated the misregistration is practically impossible to quantify within any laminate, unless slow and expensive x-ray tooling is utilized or more accurately if destructive analyses, such as cross-sectioning, are performed on the laminate. This is a time-consuming procedure and provides information concerning alignment between adjacent layers with regard to only a very small area of the substrate. Similarly, when any substrates are made on a single multilayer laminate the traceability of a substrate or of such type of electrical device, which has been found to be defective due to interlayer misalignment, back to the parent laminate is very difficult when serialization of each substrate on each laminate is not employed. Moreover, inasmuch as the laminate may have been subject to poor alignment of the layers in only one corner or small region thereof, not all parts may be defective, and some may be good. By the same account, a substrate or device which has been cross-sectioned and found to possess a good alignment between layers from the center of the laminate may provide false information since devices formed from the corners of the same laminate will typically be subjected to the greatest degree of misalignment from a layer which is slightly rotated during stack-up or lamination within the laminate.
There are also times during processing of cofired multilayer ceramic substrates when shrinkage mismatches between dielectric and conductor features particularly at line to via connections become distorted. This can produce electrical connections which can cause risks of electrical failure during thermal cycling due to CTE (coefficient of thermal expansion) mismatches between the dielectric and conductor.
In actual practice, proper alignment and complete area overlap at these interlayer interfaces is desired; however in reality, there is frequently encountered layer-to-layer misalignment due to greensheet movement during deposition of metallized features, often as organic based pastes, drying, handling, stacking, among other fabrication steps. Similarly, incomplete paste deposition can result in poor via fill. All of these factors can result in partial interlayer overlap with the potential for thermal expansion driven conductor-to-conductor electrical interface failure. This failure mode can be encountered with ceramic substrates when copper metallization, which has a very high coefficient of thermal expansion compared to most ceramics, is stressed during thermal cycling, fails and causes an electrical open. Severe conductor to via or inter layer via misalignment may also result in electrical shorting between metallized features. Likewise failures can be caused by manufacturing process violation of minimum feature separation requirements which may be required to ensure optimum electrical performance. Presently, there are no simple, reliable tests available for non-destructive detection as spacing violations in laminated parts. High-resistance shorts between metallized features can also influence the electrical performance of a semiconductor or electronic package. Ideally, there should be available a method to quickly and non-destructively determine whether an individual device, such as that resulting from the singulation of a multi-up laminate, has good alignment so as to provide an early screening for these types of defects.
2. Discussion of the Prior Art
Although various devices and methods have been developed in the technology for implementing the testing of the electrical integrity of semiconductor devices, particularly such as those which employ multilayer substrates possessing electrical interfaces, and which have electrical devices arranged on the surfaces thereof, including the testing of via to via alignment and layer interface alignment, these are primarily limited in scope and also fail to provide for the desirable kinds of non-destructive testing of these substrates and devices. Fulford, Jr. et al. U.S. Pat. No. 5,916,715 pertains to a process utilizing lithographically deposited metallized features in order to determine the layer alignment of these features for a multilayer substrate of a device. Each and every layer of the multilayer device requires multiple metallized features in order to provide a determination as to whether alignment is obtained within a specified range of microns. The testing which is implemented through the intermediary of this process is not employable for thick film alignment assessments inasmuch as it consumes considerable space on every greensheet layer during processing.
Hanson U.S. Pat. No. 5,863,446 describes an electrical arrangement for extracting layer to layer registration, wherein an alignment test feature is employed in an organic laminate for an electrical device. Resistors are positioned at strategic surface locations in order to determine lateral alignment of laser drilled conductive vias, such vias being produced in laminates requiring precise control of laser energy so as not to pierce the resistive layer which will be employed in order to assess the degree of misregistration, and necessitating precise placement of vias. It is difficult to produce laser holes in a fired ceramic substrate, and even more complex to be able to stop at a buried resistive layer and to subsequently metallize this via to a surface pad which can be probed for electrical integrity.
Lee et al. U.S. Pat. No. 5,756,146 discloses a method which permits optical inspection of metal lines in or on a transparent substrate. To the contrary, ceramic substrates, as well as most high performance chip carriers are not transparent and thus neither a laminated or sintered substrate as employed in the present construction would be suitable for the type of inspection testing disclosed in this patent.
Bayer et al. U.S. Pat. No. 5,283,107 relates to a process for producing a multilayer substrate with a prelaminated building block arrangement of wiring units to assemble a complete wiring pattern for each substrate. There is no test capability provided which will enable interlayer, intrablock or interblock alignment to be investigated nor for testing the integrity of adjacent through-vias, wiring traces or I/O (Input/Output) pads with regard to wiring continuity between selected electrically conductive surface elements and internal metallized features.
Zingher U.S. Pat. No. 4,578,279 relates to the inspection of multilayer ceramic circuit modules through the intermediary of electrical inspection of unfired greensheets. However, this does not enable implementation of any alignment test features to quantify alignment of deposited layer metallization on dielectrics or interlayer stacking alignment.
McMahon U.S. Pat. No. 4,441,075 provides for a circuit arrangement enabling the testing of each individual chip and interchip connection in a high density packaging structure having a plurality of interconnected chips without any physical disconnection. However, there is no capability of providing for non-destructive testing of substrate interlayer shifting, or testing for misalignment or masking offsets relative to the filling of vias analogous in a manner provided for by the present invention.
SUMMARY OF THE INVENTION
Accordingly, in order to obviate or ameliorate the drawbacks and limitations of the prior art, applicants have developed a number of test structures which can be employed in order to provide, essentially non-destructively, visual and electrical test data concerning the alignment of electrically conductive and dielectric features which are deposited on multilayer substrates, and which are typically used in chip carrier packaging. These testing features can detect the alignment of metallized features placed on a single layer, as well as provide informative data regarding measureable misalignment of conductive features between layers of a potentiality which can detrimentally impact electrical reliability as well as electrical performance, particularly at very high frequencies where conductive feature-to-feature misalignment may at times produce detrimental signal reflections.
These alignment features can be readily incorporated into pattern deposition masks, such as silk-screening or metal masks employed to deposit conductive features on unfired greensheets using conductive metal pastes. These features can be structured to detect the amount of misalignment that is typically encountered due to mask-layer placement misalignment, greensheet distortion originating from handling, improper placement of via holes used to provide layer to layer electrical interconnectivity, and the like. These alignment features facilitate misalignment detection by means of visual or optical assessment of spacing violations or irregularities between deposited metallized or conductive features.
Applicants further provide inventive test features in the substrate capable of testing the alignment of layer to layer metallized features after the multilayer substrate has been assembled, and in some instances heated to consolidate the assemblage into an electrically functional electronic device, such as a semiconductor chip carrier. The test features allow the assessment of worst case layer misalignment, using surface pads which connect to electrically testable nets able to quantify the degree of (mis)alignment between any two layers, and which can also be used to provide informative data as to which layers of a multilayer laminate or substrate are misaligned.
The information which is acquired from these test features can be utilized to improve electrical manufacturing yields by early detection of conductive feature misalignment which can cause shorts and opens in the manufactured electrical device. The test data can also be used to provide diagnostics of pattern deposition equipment indicative of tooling wear, improper setup or other mechanical malfunctions encountered during production. For high frequency RF applications, typically above 10 GHz, where alignment of layers and features within the package is critical to minimize signal reflections that can adversely affect performance, the test features can be used to confirm the alignment of conductive features and provide monitors during the manufacturing process to quickly indicate potential alignment shifts. These test features would be made as through-via columns (top to bottom) in the substrate to maximize the stress on the via columns and test all the interfaces of the metallization within the substrate. In order to further stress the device, it may be subjected to a very low temperature prior to testing so as to still further stress the interfaces by maximizing the contraction of a metal via column due to CTE mismatch with the dielectric material of the substrate layers. This can be accomplished by immersion in liquid nitrogen or other suitable cryogenic media or methods. Electrical “opens” testing can be performed during the time the part is maintained at subambient temperatures.
During the subambient temperature or thereafter the “Top to Bottom” and “Top to Top” connections would be tested for latent opens signatures by known latent defect detection methods. This test structure can be provided for every substrate design and testing can be performed for every substrate. This is necessary since there is typically no traceability to a single laminate after singulation. There is also no simple, accurate non-destructive test available after laminating in order to assess feature to feature alignment.
Accordingly, it is an object of the present invention to provide test structures which will facilitate the obtaining, in non-destructive modes, visual and electrical test data regarding the alignment of electrically conductive and dielectric features which are incorporated within or deposited on multi-layer substrates.
Another object of the invention is to provide test features which can detect and impart informative data regarding measurable misalignment of conductive features on a single substrate layer, as well as intermediate multilayer interfaces of a substrate to ascertain electrical reliability and performance.
A further object resides in the provision of test features to detect the extent of misalignment encountered during mask-layer placement, greensheet or dielectric layer distortion and improper via placement wherein-the test features may be incorporated into pattern deposition masks, such as silk-screening and metal masks.
Yet another object resides in the provision of novel methods employed through the utilization of the test features as described herein in accordance with the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference may now be made to the following detailed description of preferred embodiments of the invention, taken in conjunction with the accompanying drawings; in which:
FIG. 1 a illustrates the vertical sectional view through a portion of a multilayer substrate, such as a ceramic substrate, including test pads arranged in a corner of the substrate;
FIG. 1 b illustrates the positioning of the test pads of FIG. 1 a intermediate I/O pads on the substrate;
FIG. 2 a illustrates an ideal alignment of the various layers in the substrate of FIG. 1 a of the vias formed therein;
FIG. 2 b illustrates a typical or allowable degree of misalignment in the vias formed in the different substrate layers of FIG. 1 a ; FIG. 2 c illustrates a potential risk of electrical shorts or opens by an excessive offset of the vias in the successive substrate layers of FIG. 1 a;
FIGS. 3 a and 3 b illustrate, respectively, test structures for assessing screening alignment for via fill and line deposition; in which FIG. 3 a illustrates, in an exploded view, the different layer alignment and extent of misalignment of the via filled with paste connections; whereas FIG. 3 b illustrates, on an enlarged scale, a top plan view thereof;
FIG. 4 illustrates, in a vertical sectional view, the connection of internal misalignment determination features of the conductive lines and vias intermediate the various layers with regard to surface metallized features;
FIG. 5 a illustrates the line bending test features of, respectively, a through-via stack presintered, top to bottom; whereas in FIG. 5 b there is disclosed a through-via stack post-sintered, including an electrical test for signal integrity from top to bottom;
FIGS. 6 a through 6 c illustrate, in sequence, the filling of vias, showing the procedure in providing the mask opening with a properly aligned mask relative to the greensheet feature;
FIGS. 6 d and 6 e illustrate, in sequence, the placement of a misaligned mask relative to the greensheet feature showing the improperly filled via;
FIGS. 7 a and 7 b illustrate, respectively, the novel mask with the inventive alignment feature in FIG. 7 a surrounding the via fill opening in the mask on a punched substrate greensheet; in which FIG. 7 b illustrates the filled via and alignment feature with paste filled through the mask;
FIGS. 7 c and 7 d illustrates, respectively, a misaligned mask relative to the via hole, and the filled via with the misaligned mask showing the irregularity in the deposition of the paste fill material; and
FIG. 7 e illustrates in an enlarged plan view, the mask of FIG. 7 a over the via properly aligned to provide a fill as illustrated in FIGS. 7 a and 7 b ; whereas FIG. 7 f illustrates a plan view of a misaligned mask showing the irregular fill of FIG. 7 d.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Reverting in specific detail to the drawings, FIG. 1 illustrates a vertical sectional view through some of the layers 12 , 14 , 16 , 18 — 20 and 22 of a ceramic multilayer substrate 10 , forming interfaces A, B, C, D, E—X; Y and through Z, and including top test pads 24 and 26 and a bottom test pad 28 wherein the bottom test pad 28 is a BSM shorted test pad.
Indicated by the through-via columns or stacks 30 and 32 in FIG. 1 a , is the misalignment among the various layers 12 , 14 and 16 , whereas the layer pairs 16 and 18 , as well as 20 and 22 are well aligned relative to each other.
As indicated, each through-via stack 30 , 32 shows a degree of misalignment at the interfaces which is less than one-half (½) the diameter of the via, so as to essentially provide a permissible extent of misalignment; in effect, the functioning of the device would not be adversely affected.
Referring to FIG. 1 b , the test pads 24 , 26 , 28 are preferably located in the substrate corner region intermediate I/O pads 36 , wherein the extreme corners are employed to maximize sensitivity, inasmuch as any misalignment is increased in its extent from the center of the substrate 10 towards the edges or corners thereof. Consequently, the use of the corners to show an allowable amount of misalignment by testing the electrical conductivity between the upper and lower test pads, is employed to permit dispositioning of the substrate 10 if necessary.
As shown in FIGS. 2 a through 2 c , FIGS. 2 a and 2 c illustrate respectively via alignment, or misalignment in the areas wherein FIG. 2 a illustrates the ideal alignment of the layers 12 , 14 , 16 relative to a through-via stack 30 . In that instance, there is practically no misalignment at the interfaces between adjacent layers, so as to thereby verify that there is a good degree of conductivity present between the various substrate layers and electrical lines.
As shown in FIG. 2 b , in that instance there is a permissible extent of radial misalignment encountered in stacking between the successive layers 12 , 14 , and 14 and 16 of the through-via portions. However, each radial offset of adjacent layers is less than or only about one-half (½) the via diameter. This is a radial offset which misaligns the layers 12 , 14 , 16 to within a permissible degree, which will still enable proper and reliable functioning of the electrical components of the device.
With regard to the more extensive radial interlayer misalignment, as shown in FIG. 2 c , there is a potential risk of operating failure or malfunctions, inasmuch as the uppermost layer 12 relative to the second layer 14 is offset about three-quarters (¾) the diameter of the via 30 ; while between the second layer 14 and the third layer 16 there is an offset of almost the entire via diameter. This degree of misalignment or radial offset can produce an electrical disconnection adversely affecting the reliable functioning of the device during intended operation.
As wiring density increases and at high frequencies smaller sized vias, for instance (1-3 mils in diameter), with less current carrying capacity, require an improved degree of interface alignment between substrate layers in order to avoid high frequency losses and internal substrate heating due to the lack of adequate contact areas being afforded in the continuity of the via stack through the collective substrate layers.
Referring to FIGS. 3 a , 3 b and 4 , presently vias 30 and conductive lines 40 are deposited in one pass on a greensheet. Ideally the registration between all of the deposited features on a single layer should be quite good. However due to greensheet movement and processing alignment variations adjacent layers at stack-up can misalign. The mask feature for ascertaining alignment between layers is shown in the form of a ring 42 with a gap around the via. The aligned via stack 30 is filled with conductive paste, and is connected to pads on the top of the substrate. A second via stack 31 is also deposited on each layer with lines 40 and alignment test feature 42 being deposited on each layer. Via stack 31 is connected to a test feature on the top of the substrate. The gap 44 within mask ring 42 provides indication and data as to misalignment between adjacent layers through thickness of substrate 10 . Separate via and pattern screening passes may be employed for other products, and the inclusion of a ring structure 42 as shown in FIGS. 3 b and included on layers 12 , 14 , 16 and 18 would allow determination of screening misalignment and layer stacking errors. By electrically probing the surface pads of adjacent test structure via stacks of FIG. 4 any adjacent layers or via stacks which are misaligned sufficiently to cause the via 30 to contact outer ring 42 will produce a continuous electrical path between the surface pads. The radial misalignment detection capability requires only a few test structures located at the corners of each device, and also may be designed to permit different degrees of misalignment to be analyzed within a device, whereby shifts during manufacturing processing can be readily and rapidly detected. This is implemented by changing the gap 44 between the via 30 and the detection ring 42 as illustrated in FIG. 4 of the drawings, and at the layer 16 - 18 interface and the layer 18 - 20 interface. Thus, further multiple features may be incorporated for determining the degree of alignment or misalignment at each successive layer interface. Of course multiple test features with different degrees of misalignment sensitivity can also be placed on any layer.
Moreover, other test structures can be employed in the substrate 10 to assess the degree of line bending, after sintering of cofired ceramic substrates or lamination of organic dielectric layers, as shown in FIG. 5 a of the drawings, wherein bending is encountered due to extremely long via stack lengths, so that these can be made to assess microstructural uniformity of the sintering or lamination process and material compatibility. As shown in FIG. 5 a and 5 b , wherein there is shown an example of the structure used for line bending measurements, the greater the length of the via column, the greater is the stress on the via to the line interconnect and the greater the sensitivity to potential problems caused; for example, as shown in FIG. 5 b , by sintering behavior (impurities, powder metal sintering control variations and the like), furnace atmosphere abnormalities, excessive lamination temperatures and/or pressure and the like. The line width or widths can also be changed; i.e. made in a range of widths, so as to increase the sensitivity of the line to the via to failure. The thinner the line, typically the more sensitive it is to failure. This type of test structure is particularly useful for large, thick high value laminates, which are at greater risk to this type of defect. Pads 24 and 28 terminations are used to electrically test continuity of the line bending on the substrate surfaces. To increase the sensitivity of the electrical testing the device can be electrically tested at temperature below ambient, typically <−50° C. to increase the CTE mismatch of the metal to dielectric at the interface and provide early detection of latent defects by stressing the line to open.
As described with regard to testable structures, FIGS. 6 a through 6 e , and FIGS. 7 a and 7 f show visual and electrical test configuration for screening misalignment on an individual dielectric layer. In the embodiment of FIGS. 6 a through 6 e , there is shown a punched via 50 in a substrate 52 . FIG. 6 b shows a well aligned mask 54 positioned over the via and FIG. 6 c shows the via 50 after filling it with a conductive paste 56 . In contrast, FIG. 6 d shows a poorly aligned or misaligned mask-to-via with FIG. 6 e illustrating the resultant offset and irregular fill of the paste through the mask into the via and on oversize via surface features.
FIGS. 7 a through 7 f show the proposed test structure that would provide a 1 mil wide ring-shaped visual and electrical separation of mask 62 to via 64 misalignment. In FIG. 7 a and 7 b there is shown to be a good alignment between the alignment test features 60 deposited by mask alignment rings 61 in the mask 62 and the greensheet 66 . Screening this mask region centered over a punched via 54 in a greensheet 66 with paste will produce a filled via and a segmented ring around the via which will not be shorted together. Contrastingly, in FIG. 7 c the mask opening is not well aligned with the via. Screening this mask region with paste will cause some of the paste to flow under the 1 mil wide mask ring 61 and short the via 54 to the alignment test feature 60 , as can be seen in FIG. 7 d . If electrical connections are made to the outer alignment feature and conducted by vias to the surface of the parts, the alignment can be confirmed by testing for continuity between the via and the outer ring or ring segments. FIGS. 7 e and 7 f show examples of, respectively, well aligned and misaligned screened features from, respectively, FIGS. 7 b and 7 d on the greensheet. The width of the space between the vias and ring-shaped alignment features produced by mask ring 60 can be changed to adjust the sensitivity of the structure to misalignment detection.
These test structures 60 would ideally be located on the perimeter or edge portions of the layers or substrate patterns to provide the maximum sensitivity to screening misalignment. They could be outside the electrically active wiring area for visual detection or within the substrate for electrical testing.
In particular, as shown in FIGS. 7 a and 7 b , a ring-shaped mask 62 with alignment feature 60 surrounding the via fill opening is provided and positioned on the substrate or greensheet 66 , and thereafter, as shown in FIG. 7 b , the appropriate paste 56 is applied through the mask filling the via 64 and alignment feature 60 . The filled vias and alignment surface features are well aligned, showing the proper positioning of the paste and ring, as verified by the plan view of FIG. 7 e of the drawings.
To the contrary, a misalignment as shown in FIGS. 7 c and 7 d of the drawings of the mask 62 with feature 60 relative to the greensheet 66 over the via hole will cause the paste to flow under mask feature 61 into the space formed between the via opening and the greensheet, and thereby upon filling the via with the paste, and removal of the mask it is clearly indicated visually that there is a misalignment and the fill is improper, as shown in FIG. 7 f of the drawings. Consequently, this may provide a flow of the conductive material in a direction so as to adversely affect any electrical interconnects between the via and electrical lines.
The surface test pads for testing electrically are preferably made approximately 4-12 mils in diameter so that they can be easily probed. The pads can be located and designed as fiducials between I/O pads on the bottom of the device so as to minimize area consumption used for I/O connections. Wiring can connect from the pads to the edge of the device to pass outside the “active area”, if desired.
Another method to allow the detection of misaligned layers at stacking is by punching a set of vias “off grid” by a fixed amount. These would be connected to the surface of the substrate and misalignment between layers would be detected by the opening of a circuit when the vias are so misaligned that they no longer make electrical contact.
A drawback of this technique is that the planar detection of misalignment is not 360 degrees (radially) unless a larger number of vias are used.
This technique can also be cumbersome during manufacturing when using an fixed tooling since the “off grid” vias usually need to be punched separately with an adverse impact on machine efficiency. A gang punch can be made to have all these “off grid” via in the design more efficiently.
While this invention has been particularly shown and described with respect to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in forms and details may be made without departing from the spirit and scope of the present invention. It is therefore intended that the present invention not be limited to the exact forms and details described and illustrated, but fall within the scope of the appended claims.
|
Multilayer substrates, are fabricated with the incorporation therein of non-destructive test structures utilized to provide visual and electrical test data to facilitate the ascertainment and assessment of potential electrical interface failures. Furthermore, there are provided embedded structures in multilayer substrates, such as are employed in chip carrier packaging, so as to facilitate electrical testing for via to via alignment and interface layer alignment, and to enable the testing of conductive interface electrical integrity of multilayer electrical devices.
| 7
|
BACKGROUND OF INVENTION
[0001] This invention relates generally to educational devices. More specifically, the invention relates to reading, spelling, pronunciation and vocabulary educational devices, and many other creative uses.
[0002] Methods and devices for teaching or learning how to read are known in the art. These methods often provide a reference guide with keys to pronunciation using pictures to show how a letter or group of letters sounds. Some use question and answer methods. Others use a technique of lining up the word with a picture representing that word. Some devices have a movable slide or wheel that changes the letters so the user can form his own words. Still others have a mechanism that exposes an additional letter of a word with each move for a predetermined list of words.
[0003] The prior art devices and methods have their value, but none of them addresses the needs of a slightly more advanced reader. In addition, the prior art devices are often large, rigid and cumbersome. Many of them only have a limited number of available words to teach. As the user develops more reading ability, he “outgrows” many of the prior art devices. Other prior art devices prove frustrating to more advanced readers because they are too inconvenient to carry and use with more advanced reading materials. Therefore, what is needed is a new device and method that will allow a user with some reading skills to ascertain the pronunciation and meaning of unfamiliar words.
[0004] It is an object of the present invention to provide a tool to enable one to learn the pronunciation and meaning of words.
[0005] In accordance with this object, this invention is intended to provide a method of using a tool that isolates a portion of a word to enable one to look to familiar syllables and root words to learn the pronunciation, meaning and remember the spelling of words.
[0006] Still other objects, advantages, distinctions and alternative constructions and/or combinations of the invention will become more apparent from the following description with respect to the appended drawings. Similar components and assemblies are referred to in the various drawings with similar alphanumeric reference characters. This description should not be literally construed in limitation of the invention. Rather, the invention should be interpreted within the broad scope of the further appended claims.
SUMMARY OF THE INVENTION
[0007] The present invention provides a device, a kit and a method for helping an individual learn the pronunciation, spelling and meaning of a word. The device comprises a word isolator including a window and a slide. The window is placed over the unfamiliar word. The slide can cover the entire word, expose just a portion of the word, or expose the entire word. In practice, the user, when faced with an unfamiliar word, places the word isolator over the word with the slide fully covering the word. He gradually moves the slide to expose part of the word through the window. The user then uses his knowledge of individual letter sounds, such as consonants and vowels, and multiple letter sounds, such as consonant blends, diphthongs, prefixes and suffixes to determine the pronunciation of a syllable. Then he exposes the word, syllable by syllable, until the user can pronounce the unfamiliar word.
[0008] The present invention can also be used to help determine the meaning of an unfamiliar word. The user places the word isolator over the text with the slide moved so the root of the unfamiliar word is exposed in the window. The user ascertains the meaning of the root of the word, and then he adds the meaning of the prefix or suffix to the word to learn the meaning of the unfamiliar word. In the case of a compound word, the user can expose one word of the compound word at a time to understand the meaning of the whole word. Use of the word isolator may even encourage some students to read because, just when frustration sets in at finding an unfamiliar word, the student is empowered with a learning tool that appears to be a toy.
[0009] In addition, the present invention can be provided in a kit form. The user obtains a kit which includes the parts of the word isolator, in unassembled form. The parts may be pre-cut individual pieces, a perforated template, or a pre-printed template for cutting. The user then follows the directions to assemble and use the word isolator.
[0010] The present invention can be provided in pattern form. Once the pattern is provided, the user can make the word isolator out of any convenient material, in any quantity. Once traced from the pattern, the user can enlarge or shrink the tracing to customize the word isolator for his particular use.
[0011] The word isolator can be used in various sizes and types of books. Unlike any known prior art, the structure of the word isolator allows it to flex along the curve of the page of a book. One embodiment contains a flap that can be lifted to expose the entire window for large fonts, or folded partially down to create windows of various heights for words written in smaller fonts.
[0012] The word isolator can be used in learning games. For example, the word starts totally concealed. The teacher tells the students a category. The word is revealed one letter at a time until a student guesses the word. Another game could include covering one of the student's spelling words. The student says one letter at a time until the word is spelled correctly. If the student makes a mistake, he covers the word and starts again.
[0013] Additionally, the word isolator can be used in other subjects. For example, the answers to math problems can be covered with the slide, and uncovered after the student works the problem. Adults and children learning English as a second language can use this device to help master their new language. It can be used as a study aid for any kind of fill-in-the-blank type of worksheet. Once the student fills in the worksheet, he uses the word isolator to hide the answers during review and self study. The word isolator will encourage the student to study because of the positive reinforcement felt as he uncovers each correct answer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of the preferred embodiment of the word isolator with its slide shown within the window.
[0015] FIG. 2 is a template for the window portion of the preferred embodiment of the word isolator.
[0016] FIG. 3 is a template for the slide portion of the preferred embodiment of the word isolator.
[0017] FIG. 4 is a top view of the preferred embodiment of the word isolator shown exposing part of a word.
[0018] FIG. 5 is a top view of the preferred embodiment of the word isolator shown exposing the whole word.
[0019] FIG. 6 is a side view of the preferred embodiment of the word isolator along line 6 - 6 of FIG. 1 .
[0020] FIG. 7 is one embodiment of a template for a user assembled word isolator.
[0021] FIG. 8 is one embodiment of a pattern for use in creating multiple or custom sized word isolators.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] As shown in FIGS. 1-3 , the present invention may be formed from separable components referred to as the window portion 20 , and the slide portion 30 , which can be easily assembled with one another to form a completed construction. Window portion 20 includes slots 40 A and 40 B extending adjacent the top and bottom of an opening 35 A. The slide portion 30 has tabs 50 A and 50 B near a first end of the slide portion 30 , which tabs extend through slots 40 A and 40 B in the window portion 20 to secure the slide portion 30 and the window portion 20 to one another. A handle 60 is preferably provided near the second end of the slide portion 30 which extends from the window portion 20 .
[0023] FIGS. 2 and 3 show the separable components of the word isolator 10 . FIG. 2 shows a template for the window portion 20 of the word isolator 10 . Openings 35 A and 35 B are cut so they align with one another when the window portion 20 is folded along line 25 . Slots 40 A and 40 B are preferably cut so they are approximately equidistant from the opening 35 A. FIG. 3 shows a template for the slide of the word isolator 10 . To construct the word isolator, tabs 50 A and 50 B are folded at lines 55 A and 55 B, respectively and they are inserted into slots 40 A and 40 B, respectively, of window portion 20 . Then tabs 50 A and 50 B are folded down against the window portion 20 , creating a “wrapping” effect. Next, the window portion 20 is folded along line 25 , lining up openings 35 A and 35 B. Finally, the handle 60 is created by folding slide portion 30 at line 65 .
[0024] Use of the word isolator is shown in FIG. 4 . The slide portion 30 is placed inside the window portion 20 covering most of the unfamiliar word UNCOVERING. The letters UN show through the opening 35 , and the letters COVERING are masked by the slide portion 30 . The user first determines the sound of the letters in the first syllable UN, then he uncovers the next portion, COV and determines its pronunciation. He continues uncovering the syllables ER and ING until he determines the pronunciation of the entire word. The user also notes the meaning of the prefix UN, the root word COVER, and the suffix ING to learn the meaning of the word. FIG. 5 shows the entire word UNCOVERING exposed by the slide portion 30 in the opening 35 .
[0025] FIG. 6 shows a cross section of the word isolator looking along the line 6 - 6 of FIG. 1 . The window portion 20 is shown folded along line 25 . The handle 60 is shown folded up along line 65 . The tabs 50 A and 50 B are folded at lines 55 A and 55 B respectively and inserted into slots 40 A and 40 B respectively. Tabs 50 A and 50 B are then folded down and in towards the opening 35 A of the word portion 20 creating the “wrapping” effect referenced above.
[0026] FIG. 7 shows an embodiment of the present invention when provided in a template form. The template 60 includes the window portion 70 and the slide portion 90 with markings for the window cutouts 75 A and 75 B, the slots 80 A and 80 B for the slide portion flaps 95 A and 95 B, and the handle 100 . The template 60 may include perforated lines for easy removal of the pieces, or it may be pre-printed for cutting.
[0027] FIG. 8 shows an embodiment of the present invention when provided in pattern form. Once the pattern 110 is obtained, the user can make the word isolator out of any convenient material, in any quantity. After tracing an outline from the pattern 110 , the user can enlarge or shrink the tracing to customize the word isolator for his particular use. For example, a teacher would use a large word isolator at the chalk board for demonstration purposes, while the students use smaller ones at their desks. The word isolator could also be customized to accommodate various fonts as found in many early reading books.
[0028] The word isolator can be used in learning games. For example, the teacher starts with a word or an answer totally concealed. The teacher tells the students the category for the word, or asks a question. The word is revealed one letter at a time until a student guesses the correct answer. Another game could include covering one of the student's spelling words. The teacher points to a student and that student says the first or next letter of the spelling word. Play continues until the word is spelled correctly. The students could use the word isolator for independent play and study also. The student spells the word to himself uncovering one letter at a time. If the student makes a mistake, he covers the word and starts again.
[0029] Although the invention has been described in terms of specific embodiments and applications, persons skilled in the art can, in light of this teaching, can generate additional embodiments without exceeding the scope or departing from the spirit of the claimed invention. In addition, specific features of the invention are shown in some drawings and not in others for convenience only, as each feature may be combined with any or all of the other features in accordance with the invention. Accordingly, it is to be understood that the drawings and description in this disclosure are proffered to facilitate comprehension of the invention and should not be construed to limit the scope thereof.
|
An educational device and method in which a user can learn the pronunciation and meaning of words using a word isolator with a window and a slide. The word isolator is placed over the unfamiliar word. The slide is manipulated to expose only a portion of the word at a time, thereby helping the user break down and identify the unfamiliar word.
| 6
|
CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims priority from U.S. Patent Application No. 61/417,384 filed Nov. 26, 2010.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
Not Applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a toilet bowl cleaning device where the inner surface of the toilet bowl can be cleaned around the entire circumference of the toilet bowl at locations below the toilet waterline, and/or locations at the toilet waterline, and/or locations above the toilet waterline, and/or locations under the toilet rim. The toilet bowl cleaning device includes a hand or foot actuated lever for releasing a fluid from the container into a fluid delivery system and a clip for mounting a fluid sprayer adjacent an inner wall of the toilet bowl wherein the clip can be adjusted to fit different size toilet bowls.
2. Description of the Related Art
Toilet bowls require care to prevent the buildup of unsightly deposits, to reduce odors, and to prevent bacteria growth. Traditionally, toilet bowls have been cleaned, deodorized, and disinfected by manual scrubbing with a liquid or powdered cleaning and sanitizing agent. This task has required manual labor to keep the toilet bowl clean.
In order to eliminate the detested manual scrubbing, various toilet bowl cleaner dispensers have been proposed. One type of dispenser comprises a solid block or solid particles of a cleansing and freshening substance that is suspended from the rim of a toilet bowl in a container that is placed in the path of the flushing water. U.S. Pat. No. 4,777,670 (which is incorporated herein by reference along with all other documents cited herein) shows an example of this type of toilet bowl cleaning system. Typically, a portion of the solid block is dissolved in the flush water with each flush, and the flush water having dissolved product is dispensed into the toilet bowl for cleaning the bowl.
Other toilet bowl cleaning systems use a liquid cleaning agent that is dispensed into a toilet bowl. For example, U.S. Pat. Nos. 6,178,564 and 6,230,334, and PCT International Publication Nos. WO 99/66139 and WO 99/66140 all disclose cleansing and/or freshening devices capable of being suspended from the rim of a toilet bowl for introducing liquid active substances from a bottle into the flushing water with each flush. In these under the toilet rim devices, the liquid active substances are delivered downward from a reservoir to a dispensing plate that is supported by a base that is suspended from the toilet bowl rim. The device is suspended from the toilet rim such that the flow of flush water from the toilet contacts the dispensing plate during a flush. The flush water carries the liquid active substances that are on the dispensing plate into the toilet bowl to clean and freshen the toilet.
Other toilet bowl dispensers use an aerosol deodorizing and/or cleaning agent that is dispensed into a toilet bowl through a conduit attached to the toilet bowl rim. For example, U.S. Pat. No. 3,178,070 discloses an aerosol container mounted by a bracket on a toilet rim with a tube extending over the rim; and U.S. Pat. Nos. 6,029,286 and 5,862,532 disclose dispensers for a toilet bowl including a pressurized reservoir of fluid, a conduit connected to the source of fluid, and a spray nozzle which is installed on the toilet rim.
One disadvantage with these known toilet rim dispensing devices is that these devices may only apply the deodorizing and/or cleaning agent to one location in the toilet water or a limited area in the toilet water or on the inner surface of the toilet bowl. As a result, the cleaning of the inner surface of the toilet bowl may be limited to an area of the toilet bowl near the device. This is a drawback as it is desirable to obtain uniform application of cleaning fluid in the entire toilet bowl.
U.S. Pat. No. 7,603,726 sets forth, among others, an automatic or manual toilet bowl cleaning device where the inner surface of the toilet bowl is cleaned around the entire circumference of the toilet bowl. In one embodiment illustrated in that application, the downstream end of a fluid conduit terminates in a rotating nozzle capable of spraying the fluid outwardly onto the inner surface of the toilet bowl. The fluid is stored in a container until the fluid is released into the fluid conduit. Various methods for triggering the release of fluid from the container are described in U.S. Pat. No. 7,603,726.
Several techniques are also available to provide adjustment for devices attached to the rim of a toilet bowl. Adjustment has been generally limited to either (1) accommodating toilet bowl rims of varying width, as shown in U.S. Pat. No. 6,029,286 wherein a ratchet arrangement between two members of the hook is used to adjust the hook for varying rim widths, or (2) attempting to accommodate the depth of the rim and bowl geometry by adjusting the vertical position of the device below the rim. For example, U.S. Pat. No. Re. 32,017 and U.S. Pat. Nos. 6,898,806 and 7,114,199 incorporate a ratchet arrangement between the hook and the body to allow discrete vertical adjustment of the device below the rim of a toilet bowl. Furthermore, U.S. Pat. No. 6,675,396 allows for continuous adjustment of the body with respect to the rim by the use of a friction fit wherein a flat bar hook is wedged within a hollow channel formed within the body. U.S. Patent Application Publication Nos. 2007/0240252 and 2008/0017762 also show various clips for mounting a nozzle near the rim of the toilet bowl.
However, there is still a need for improved devices for triggering the release of fluid from the container. There is also still a need for an improved clip for mounting a nozzle near the rim of the toilet bowl having adjustment means that adequately position the nozzle so that the dispensed fluid reaches the extremes of the inner surface of the toilet bowl when the toilet bowl has an asymmetric or elongated rim/inner surface configuration. Thus, even further improvements to this technology would be beneficial to consumers.
SUMMARY OF THE INVENTION
The foregoing needs can be met with a toilet bowl cleaning and/or deodorizing device according to the invention that delivers a chemical into the toilet bowl. The term “chemical” or “chemistry” means one chemical or a mixture of chemical ingredients. Various cleaning and/or deodorizing chemicals are suitable for use with a toilet bowl cleaning device according to the invention. The toilet bowl cleaning and/or deodorizing device includes appropriate chemistry and a dispensing system. As used herein, the term “cleaning” also includes sanitizing and/or disinfecting, and the term “deodorizing” also includes freshening.
Regarding the chemistry, a chemical is applied directly onto the inner surface of the toilet bowl and/or into the toilet water so as to clean and freshen the toilet bowl. If applied to the inner surface of the toilet bowl, the chemical will typically be a liquid (single or multiple chemistries). If added to the toilet water, the chemistry can also be a liquid (single or multiple chemistries) that is added to the water to act as a preventive, or to create an environment that will work to clean the toilet automatically.
With respect to the dispensing system, the system includes several subsystems which are the means for applying the appropriate chemistry to the inner surface of the toilet bowl to conduct the cleaning process. The dispensing system may include (but is not limited to): (i) a chemistry storage container; (ii) a chemical propulsion system; (iii) a chemical delivery system; and (iv) a toilet interface.
The chemistry storage container is used to hold and store the chemistry used to clean the toilet bowl. Non-limiting examples include a standard plastic bottle, such as that found on a trigger sprayer.
The chemical propulsion system provides a method of providing the appropriate energy to the chemistry to move it through the delivery system so that it can move from the storage container to the appropriate area within the toilet bowl. Examples of this subsystem include a pump or pumping mechanism to move a liquid such as a vein pump, bellows pump, impeller driven pump, piston pump, peristaltic pump or gear driven pump.
The chemical delivery system provides a method of moving chemistry from its storage container to the appropriate area within the toilet bowl. This delivery subsystem can include a hose and a sprayer (e.g., a nozzle).
The toilet interface provides a means and method of attachment to the toilet to keep the hose out of the way, keep it uncrimped, and secure the sprayer nozzle into place on the toilet rim or toilet lid.
These subsystems work together to deliver the appropriate chemistry (using predetermined amounts) to deliver the desired consumer benefit.
Therefore, in one aspect, the invention provides for a holder for receiving a container with fluid that has a valve stem, where the holder includes a base with a manifold. The manifold has an inlet, an outlet, and a fitment to engage the valve stem. The inlet is in fluid communication with the outlet. The holder also includes a triggering device that has a first flange on one end and a second flange on an opposite end. The triggering device is configured to move between a first position and a second position upon pressure being supplied to at least one of the first flange and the second flange, and the triggering device engages the container in the second position such that the fitment moves the valve stem relative to the container to supply the fluid to the inlet.
In another form, the invention provides for a holder wherein the first flange extends away from the triggering device in a first direction and the second flange extends away from the triggering device in a second direction. The first direction is opposite from the second direction.
In yet another form, the invention provides for a holder wherein the first flange forms a top portion of the holder.
In a further form, the invention provides for the triggering device to engage the container in the second position by contact of the first flange with the container.
In still yet another form, the invention provides for a holder wherein upon the triggering device engaging the container in the second position, the container is moved downward through contact with the first flange.
In another form, the invention provides for the triggering device to move from the first position to the second position from a user's hand applying the force to the first flange.
In yet another form, the invention provides for the triggering device to move from the first position to the second position from a user's foot applying the force to the second flange.
In another form, the invention provides for a holder with a triggering device that further includes a triggering device wall projecting from the first flange, wherein the triggering device wall is configured to support a side of the container.
In a further form, the invention provides for a holder where the triggering device wall is further configured to slide between the container and the base when the triggering device is moved from the first position to the second position.
In another form, the container includes a retainer, and the base includes two or more fingers dimensioned such that each of the fingers flexes outwardly when contacted by the retainer during installation of the container in the holder.
In yet another form, the invention provides for a holder that further includes a check valve. The check valve is downstream of the outlet.
In another aspect, the invention provides for a device for spraying an inner surface of a wall of an enclosure with a fluid. The device includes a container for the fluid, a holder for receiving a container with fluid that has a valve stem, where the holder includes a base with a manifold and a triggering device with a first flange on one end and a second flange on an opposite end and configured to move between a first position and a second position. The manifold has an inlet, an outlet, and a fitment to engage the valve stem. The inlet is in fluid communication with the outlet. The triggering device is configured to move between a first position and a second position upon pressure being supplied to at least one of the first flange and the second flange, and the triggering device engages the container in the second position such that the fitment moves the valve stem relative to the container to supply the fluid to the inlet. The device also includes a fluid conduit in fluid communication with the outlet and a fluid sprayer and a means for attaching the fluid sprayer near the inner surface of the wall of the enclosure.
In one form, the device is configured such that the first flange extends away from the triggering device in a first direction and the second flange extends away from the triggering device in a second direction. The first direction is opposite from the second direction.
In another form, the invention provides for a device wherein the first flange forms a top portion of the holder.
In a different form, the invention provides for a device such that the triggering device engages the container in the second position by contact of the first flange with the container.
In yet another form, the device is configured such that upon the triggering device engaging the container in the second position, the container is moved downward through contact with the first flange.
In another form, the invention provides for a device, wherein upon the triggering device engaging the container in the second position, fluid exits the container, travels through the conduit, moves through the fluid sprayer, and is sprayed on the wall of the enclosure.
In still another form, the invention provides for a device wherein the enclosure is a toilet bowl.
In yet another aspect, the invention provides for a retention mechanism for a dispenser including a container and a holder for receiving the container in an opening of the holder. The retention mechanism includes a retainer dimensioned to engage the container, the retainer including a projection extending outwardly from the retainer with a cavity in the projection, and a fitment which forms part of the holder and is dimensioned such that the fitment is received within the cavity of the projection. The cavity has a corresponding shape to the fitment.
In one form, the invention provides for a retention mechanism where the cavity and fitment are cylindrical in shape.
In a different form, the retention mechanism also includes a base wall that forms part of a base of the holder, where the base wall is configured to support a portion of the container.
In yet another form, the invention provides for a retention mechanism that also includes a triggering device wall that forms part of a triggering device of the holder, with the triggering device wall configured to support a portion of the container.
In still another aspect, the invention provides for a refill for a sprayer system including a container holder and a fluid conduit in fluid communication with an outlet of the container holder and a fluid sprayer. The refill includes a container and a retainer connected to the container. The retainer includes a cylindrical projection extending outwardly from the retainer with a cavity in the projection.
In one form, the invention provides for a refill where the container is an aerosol can having a valve cup rim surrounding a valve stem, and the retainer includes a central annular wall dimensioned to engage the valve cup rim.
In a different form, the invention provides for a refill where a portion of the retainer engages a dome of the aerosol can.
In another form, the invention provides for a refill wherein the cavity in the projection of the retainer is configured to receive a fitment that forms part of the container holder to retain the refill in the container holder.
In another aspect, the invention provides a clip for mounting a fluid delivery device adjacent a wall of an enclosure. The clip includes a support having a first side and an opposite second side, a base attached to the support wherein the base is structured for attaching the fluid delivery device to the base, a first arm having a first section extending laterally from the support and a second section extending downward from the first section, and a second arm having a first segment extending laterally from the support and a second segment extending downward from the first segment. The first arm and the second arm have an equilibrium position in which the first section and the first segment form a first angle facing away from the second side of the support. At least one of the first arm and the second arm can be elastically deflected to create a flexed position in which the first section and the first segment form a second angle facing away from the second side of the support. The second angle is less than the first angle.
In another form of the clip, the first arm and the second arm comprise part of a helical torsion spring, and the helical torsion spring is connected to the support, and the first arm and the second arm extend from opposite sides of the helical torsion spring.
In yet another form of the clip, the base is slidingly attached to the support.
In still another form of the clip, a biasing means is attached to the base and the support for biasing the base toward an end of the support.
In yet another form of the clip, the biasing means is a spring.
In still another form of the clip, the biasing means is housed within the support.
In yet another form of the clip, the base includes a projection that extends away from the second side of the support.
In still another form of the clip, the enclosure is a toilet bowl, and the first arm and the second arm are dimensioned to hang on a rim of the toilet bowl and support the base adjacent an inner wall of the toilet bowl.
In yet another form of the clip, the second section and the second segment contact an outer surface of the toilet bowl, and the first section and the first segment contact a top surface of the rim, and the support contacts an inner surface of the toilet bowl when the first arm and the second arm hang on the rim.
In still another form of the clip, the projection contacts an undersurface of the rim when the first arm and the second arm hang on the rim.
In yet another form of the clip, the base includes a barrel for supporting the fluid delivery device.
In still another form of the clip, the base comprises a fluid inlet, and the base supports a fluid delivery device comprising a nozzle in fluid communication with the fluid inlet.
In yet another form of the clip, the nozzle comprises a bottom wall, a passageway in fluid communication with the fluid inlet at an upper end of the passageway wherein the passageway extends between the fluid inlet and the bottom wall, a channel in fluid communication with a lower end of the passageway, and a pair of walls flanking the channel and extending upwardly from the bottom wall wherein the walls are contacted by fluid to rotate the nozzle.
In still another form of the clip, the base includes a shroud surrounding a portion of the nozzle.
In yet another form of the clip, the shroud has a transverse opening that provides a fluid path from the nozzle.
In yet another aspect, the invention provides a device for spraying an inner surface of an enclosure with a fluid. The device includes a container for the fluid; a fluid delivery device through which the fluid can be applied to the inner surface of the enclosure; a fluid conduit in fluid communication with the container and the fluid delivery device; means for delivering fluid from the container through the fluid conduit and to the fluid delivery device; and a clip for mounting the fluid delivery device adjacent a wall of the enclosure. The clip includes a support having a first side and an opposite second side, a base attached to the support wherein the base is structured for attaching the fluid delivery device to the base, a first arm having a first section extending laterally from the support and a second section extending downward from the first section, and a second arm having a first segment extending laterally from the support and a second segment extending downward from the first segment. The first arm and the second arm have an equilibrium position in which the first section and the first segment form a first angle facing away from the second side of the support. At least one of the first arm and the second arm can be elastically deflected to create a flexed position in which the first section and the first segment form a second angle facing away from the second side of the support. The second angle is less than the first angle.
In one form of the spraying device, the means for delivering fluid from the container comprises a propellant.
In another form of the spraying device, the enclosure is a toilet bowl, and the first arm and the second arm are dimensioned to hang on a rim of the toilet bowl and support the base adjacent an inner wall of the toilet bowl.
In yet another form of the spraying device, there is a sleeve for holding the fluid conduit adjacent the first arm.
It is therefore an advantage of the invention to provide a toilet bowl cleaning device where the inner surface of the toilet bowl is cleaned around the entire circumference of the toilet bowl. The device provides for overall toilet bowl cleanliness by enhanced shine and the retardation of biofilm, mold and/or mildew growth. The device can deliver liquids to remove or eliminate stains (hard water, limescale, metals, organic), mold, mildew, germs, odors, and bacteria. The device can spray the entire toilet bowl and is not limited to just one small area of the toilet bowl.
These and other features, aspects, and advantages of the present invention will become better understood upon consideration of the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a perspective view of a prior art toilet bowl cleaning assembly.
FIG. 1B is an enlarged, partially exploded view, of a prior art holder/activator used therewith.
FIG. 2 is a perspective view of a holder in accordance with the invention.
FIG. 3 is an exploded, perspective view of the holder from FIG. 2 , depicting a container of fluid and retainer housed therein.
FIG. 4 is a perspective view of the base that forms part of the holder from FIG. 2 .
FIG. 5 is a cross-sectional view of the holder of FIG. 2 along line 5 - 5 .
FIG. 6 is a perspective, detailed view showing a portion of the base, including the manifold and associated fluid delivery components, from FIG. 2 .
FIG. 7 is an exploded, perspective view of a refill in accordance with the invention.
FIG. 8 is a perspective view of the assembled refill from FIG. 7 .
FIG. 9 is a top, left perspective view of a clip for mounting a fluid delivery device in accordance with one embodiment of the invention.
FIG. 10 is a front elevational view of the clip of FIG. 9 .
FIG. 11 is a rear elevational view of the clip of FIG. 9 .
FIG. 12 is a top plan view of the clip of FIG. 9 .
FIG. 13 is a bottom plan view of the clip of FIG. 9 .
FIG. 14 is a right side elevational view of the clip of FIG. 9 .
FIG. 15 is a cross-sectional view of the clip of FIG. 9 taken along line 15 - 15 of FIG. 10 .
FIG. 16 is a perspective view of a second embodiment of a holder in accordance with the invention, the triggering device of the holder being removed to show inner details of the holder.
FIG. 17 is a perspective view of the holder of FIG. 16 during installation of another embodiment of a refill in accordance with the invention.
FIG. 18 is a perspective view of the holder of FIG. 16 during attempted installation of a container without a retainer.
Like reference numerals will be used to refer to like parts from Figure to Figure in the following description of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
The invention provides a device for spraying an inner surface of a toilet bowl with a chemical. Various embodiments of the invention will now be described with reference to the Figures. The embodiments are shown and described for the purposes of illustration and are not intended to limit the invention in any way.
FIGS. 1A and 1B show a prior art toilet 10 , per FIGS. 11A-D of U.S. Pat. No. 7,603,726. Toilet 10 has a bowl 12 with a top rim 14 . A spray nozzle 16 is hooked over the rim and fed a cleaner by a fluid conduit 18 . The conduit 18 links to a holder 19 to which is mounted an aerosol container 22 . Pressing down on a foot pedal 24 causes spraying of cleaner along the toilet bowl sides. This is a non-automated system that sprays for as long as the pedal is depressed. The fluid can also be supplied from the container 22 to the fluid sprayer by different types of powered or manual pumps.
Turning now to FIGS. 2-8 , there is shown a holder 20 in accordance with the invention for delivering fluid to a conduit, such as fluid conduit 18 in FIG. 1A . As shown in FIG. 3 , the holder 20 houses a container 22 , which may be an aerosol container. The holder 20 includes a base 28 and a triggering device 30 . The base 28 (as best shown in FIG. 4 ) includes a manifold 32 .
As shown in FIGS. 3 and 4 , the base 28 may be configured such that it is assembled from two parts: a front portion 28 a , and a back portion 28 b . The front portion 28 a adjoins with the back portion 28 b to form the base 28 as shown in FIG. 4 . The base 28 may also contain a base wall 29 , as shown in FIGS. 3 and 4 . The manifold 32 is located near the bottom of the base 28 . As depicted in FIG. 6 , the manifold 32 includes an inlet 34 , an outlet 36 , and a fitment 38 . The inlet 34 is in fluid communication with the outlet 36 .
As shown in FIG. 3 , the triggering device 30 includes a first flange 40 that is located on one end 42 of the triggering device 30 and a second flange 44 that is located on an opposite end 46 of the triggering device 30 . The first flange 40 extends from the triggering device 30 in an opposite direction from the direction in which the second flange 44 extends. Furthermore, the first flange 40 forms a top portion of the holder 20 . Similar to the base wall 29 described above, the triggering device 30 may include a triggering device wall 31 .
The container 22 is housed within the holder 20 by a retention mechanism. The container 22 may be an aerosol container with a valve stem 48 , as shown in FIG. 7 . The container 22 is assembled with a retainer 50 before housing the container 22 in the holder 20 . As shown in FIGS. 7 and 8 , the retainer 50 is assembled with the container 22 by placing the retainer 50 over the dome 52 of the container 22 . The container 22 also has a pedestal 54 , which surrounds the valve stem 48 , as well as a valve cup rim 56 .
The retainer 50 includes a projection 58 that extends outwardly from the retainer 50 . A cavity 60 is formed on the interior of the projection 58 . As shown from FIG. 3 , the container 22 and retainer 50 will be housed in the holder 20 such that the container 22 is oriented with the retainer 50 facing the bottom of the base 28 , where the manifold 32 is located.
Turning now to FIG. 5 , a cross-sectional view of the holder 20 housing the container 22 is shown. In addition to the retainer 50 engaging a portion of the dome 52 of the container 22 , the retainer 50 includes a central annular wall 62 that is dimensioned to engage the valve cup rim 56 of the container 22 . As the container 22 and retainer 50 are assembled to the holder 20 , the fitment 38 is received within the cavity 60 of the projection 58 . The retention mechanism thus includes the engagement between the container 22 and the retainer 50 , and the engagement between retainer 50 and fitment 38 . As shown in FIGS. 4-8 , the cavity 60 and the fitment 38 have corresponding shapes such that the fitment 38 may be received in the cavity 60 . Although the cavity 60 and fitment 38 are shown as having corresponding cylindrical shapes, it can be appreciated that the cavity and fitment 38 could be of other corresponding shapes. The valve stem 48 of the container 22 is received within the fitment 38 . The retention mechanism may also include the base wall 29 and the triggering device wall 31 as the walls 29 , 31 may also help to retain and position the container 22 within the holder 20 .
After assembling the container 22 and retainer 50 within the holder 20 , the holder 20 may be used as part of a device 26 for spraying an inner surface 12 of a wall of an enclosure 10 with a fluid, as described in the prior art and as shown in FIGS. 1A and 1B . The container 22 and retainer 50 are placed within holder 20 , as just described, and holder 20 may be substituted for the holder 19 of the prior art in FIGS. 1A and 1B . As previously described, also forming part of the device 26 is a fluid conduit 18 , a sprayer 16 , and means for attaching the fluid sprayer 16 near the inner surface 12 of the wall of the enclosure 10 . As shown in FIG. 1A , the enclosure 10 is a toilet.
Referring back to FIGS. 2-6 , the interaction between components of the holder 20 and the container 22 will now be described such that fluid is allowed to be delivered from the container 22 , through the manifold 32 , through the fluid conduit 18 , to the fluid sprayer 16 , and on the toilet bowl 12 . The triggering device 30 is configured to move between a first position and a second position upon a force applied to either the first flange 40 or the second flange 44 by a user. Advantageously, a user may apply the force to either flange 40 , 44 to engage the container 22 . Thus, the user may use either their hand or foot to engage the first flange or the second flange, as they so desire. This may vary based on user preference, the position the user is in when the user desires to apply fluid to the enclosure 10 , or other factors.
In FIG. 2 , the holder 20 is shown with the triggering device 30 in the first position. In the first position, the valve stem 48 of the container 22 is not engaged, and thus, fluid does not exit the container 22 . However, upon pressure being supplied to the first flange 40 or the second flange 44 , the triggering device 30 will move and engage the container 22 . As the triggering device 30 is moved in a downward direction, the first flange 40 contacts the container 22 , moving the container 22 downward toward the manifold 32 on the base 28 of the holder 20 . As the container 22 moves downward, the triggering device wall 31 slides between the container 22 and the base 28 . The container 22 also moves relative to the base wall 29 . The valve stem 48 of the container 22 , however, is unable to move in a downward direction with the container 22 because the tip 64 of the valve stem 48 engages the narrowed inner surface 66 of the fitment 38 . Thus, the fitment 38 moves the valve stem 48 relative to the container 22 to supply the fluid to the inlet 34 of the manifold 32 .
Turning now to FIG. 6 , after fluid is supplied to the inlet 34 , the fluid may flow to the outlet 36 of the manifold 32 . Before entering the conduit 18 and fluid sprayer 16 , the fluid may travel through internal conduit 68 and a check valve 70 located within the holder 20 . The internal conduit 68 is in fluid communication with the outlet 36 of the manifold 32 and the fluid conduit 18 . After the user removes pressure from either the first flange 40 or the second flange 44 , the triggering device 30 will return to the first position. The user may repeat the process to provide more fluid to toilet bowl 12 .
Advantageously, the check valve 70 may be used as a way to prime the device 26 such that fluid will be maintained downstream of the check valve 70 after fluid has entered the conduit 18 from an initial use of the device 26 . This will prevent a user from having to supply pressure to the triggering device 30 to move the triggering device 30 from the first position to the second position multiple times before delivering fluid to the toilet bowl 12 .
Once the fluid is completely used from the container 22 , the container 22 and the retainer may be replaced in the holder 20 . Accordingly, the container 22 and retainer 50 , as shown in FIG. 8 , may be referred to as a “refill.”
Turning now to FIGS. 9-15 , there is shown an example embodiment of a clip 110 for mounting a fluid delivery device (e.g. a sprayer) to an enclosure such as a toilet bowl. The clip 110 is secured to the rim 14 of the toilet bowl 12 by an adjustable mounting mechanism 116 . A base 118 is supported by the mounting mechanism 116 and supports a fluid delivery device, here a nozzle 120 . A container supplies fluid via a fluid conduit 18 to the fluid delivery device 120 to be dispensed onto the inside surface of the toilet bowl in the manner of the spray nozzle 16 of FIGS. 1A-1B . The fluid can be supplied from the container to the fluid delivery device 120 in a variety of ways; for example, the fluid may be motivated by a gaseous propellant, by a manual or electric pump, a syringe, or any other suitable means. Furthermore, the execution of the fluid delivery from the container can be controlled by a variety of methods/devices, one being a timing circuit using predetermined logic to control when the fluid is dispensed.
The mounting mechanism 116 for supporting the base 118 and attaching the clip 110 to the toilet bowl 12 includes a vertical support 122 with a top casing 123 having a pin 124 surrounded by a closed coil section 125 of a helical torsion spring 126 (see FIG. 15 ) which has a first arm 128 and a second arm 130 . The first arm 128 has first section 132 extending laterally from the closed coil section 125 and a second section 133 extending downward from the first section 132 . The second arm 130 has a first segment 135 extending laterally from the closed coil section 125 and a second segment 136 extending downward from the first segment 135 . An elastic sleeve 137 holds the fluid conduit 18 adjacent the first arm 128 as it is routed on its way to the nozzle 120 in the base 118 . The support 122 is preferably molded from a polymeric material (e.g., polyethylene or polypropylene). The helical torsion spring 126 can be formed from a suitable spring material such as stainless steel.
The support 122 has a first side 138 and an opposite second side 139 . When the helical torsion spring 126 is in a relaxed undeflected position, the first arm 128 and the second arm 130 have an equilibrium position in which the first section 132 and the first segment 135 form a first angle A (see FIG. 12 ) facing away from the second side 139 of the support 122 . A user can apply a force in direction R 1 on the first arm 128 and/or apply a force in direction R 2 on the second arm 130 to create a flexed position in which the first section 132 and the first segment 135 form a second angle facing away from the second side 139 of the support 122 . As a result, the second angle is less than the first angle. This creates a larger distance between the second section 133 and the second side 139 of the support 122 and also creates a larger distance between the second segment 136 and the second side 139 of the support 122 when mounting the clip 110 to the toilet bowl 12 .
As shown in FIG. 13 , when the clip 110 has been mounted to the toilet bowl 12 (shown dashed lines in FIG. 13 ), the second section 133 and/or the sleeve 137 and the second segment 136 contact an outer surface 12 s of the toilet bowl 12 , and the first section 132 and the first segment 135 contact a top surface of the rim 14 of the toilet bowl 12 , and the second side 139 of the support 122 contacts an inner surface 12 i of the toilet bowl 12 as the first arm 128 and the second arm 130 hang on the rim 14 . The spring force provided by the helical torsion spring 126 on the first section 132 and the first segment 135 keeps the second section 133 and the second segment 136 in contact with the outer surface 12 s of the toilet bowl 12 and the second side 139 of the support 122 in contact with the inner surface 12 i of the toilet bowl 12 thereby trapping the mounting mechanism 116 to the toilet bowl 12 .
The base 118 of the clip has a back face 152 , a top front face 154 , and a bottom front face 156 that form a hollow shroud around the nozzle 120 . A transverse opening 157 is formed between the top front face 154 and the bottom front face 156 . A drain opening 158 is provided in the bottom of the bottom front face 156 for draining away fluid that may accumulate inside the shroud. The base 118 is preferably molded from plastic (e.g., polyethylene or polypropylene).
Looking at FIG. 15 , the base 118 includes a tab 160 that extends inward from the back face 152 and a plate 161 that projects outward from the back face 152 . The tab 160 is dimensioned to slide within a channel 162 of the support 122 . An extension spring 163 is attached to an inwardly directed mounting hook 164 of back face 152 of the base 118 and also attached to a mounting hook 166 of the support 122 .
A user can apply a force in direction B (see FIG. 15 ) on the base 118 to move the top casing 123 away from the base 118 . This creates a larger distance between the top casing 123 and the base 118 when mounting the clip 110 to the toilet bowl 12 . When the clip 110 has been mounted to the toilet bowl 12 , the spring 163 biases the top casing 123 toward the base 118 such that the first section 132 and the first segment 135 grip the top rim 14 of the toilet bowl 12 , and a top surface 167 of the plate 161 grips an undersurface of the toilet bowl 12 .
The base 118 includes a means to attach a fluid delivery device (e.g., nozzle 120 ) to the base 118 . In the example embodiment, the nozzle 120 is restrained laterally between a barrel 178 and a fluid inlet 180 . The fluid inlet 180 and the barrel 178 are used in conjunction to restrain lateral movement of the nozzle 120 , but allow the nozzle 120 to rotate about the nozzle axis 182 . The tubular fluid inlet 180 defines a flow path 181 , and extends downwardly from a wall 202 that is attached to the base 118 . The base 118 includes a fluid supply opening 208 that defines a flow path 209 . The fluid supply opening 208 is located in the top front face 154 of the base 118 , and may be connected to fluid conduit 18 (see FIG. 15 ).
Referring to FIG. 15 , the inner flow paths of the nozzle 120 are shown in greater detail. The nozzle 120 is preferably molded from polymeric material (e.g., polyethylene and polypropylene). The nozzle 120 includes a bottom wall 184 . An axial spindle 192 extends downward from the bottom wall 184 . Spaced apart walls 190 a , 190 b , which have a generally inverted T-shape, extend upward from the bottom wall 184 . A central fluid deflection peak 191 extends upward from the bottom wall 184 between the walls 190 a , 190 b . Passageways 186 a , 186 b are defined by the walls 190 a , 190 b and the peak 191 , and the passageways 186 a , 186 b extend upwards from the bottom wall 184 . The contour of the walls 190 a , 190 b may vary depending on the desired rotational speed of the nozzle 120 , the pressure of the fluid, the flow rate of the fluid, and the like.
As shown in FIG. 15 , the nozzle 120 is restrained laterally by inserting a spindle 192 into a recess 179 in the barrel 178 and by inserting the end of the fluid inlet 180 in depression 193 . The nozzle 120 is free to rotate about the nozzle axis 182 , but is restrained from lateral movement.
In operation, fluid is moved from a container through a fluid conduit (see, for example, the container 22 and the conduit 18 of FIG. 1A ) and into the fluid supply opening 208 . Looking at FIG. 15 , the fluid flows through the flow paths 209 and 181 , and out of the fluid inlet 180 . (The diameter of the exit orifice of the fluid inlet 180 can dictate the pressure which helps to dictate the spin rate and the distance of fluid travel off the nozzle 120 .) Fluid flows onto the top of the fluid deflection peak 191 and down the forked passageways 186 where it is directed radially outward by channels 188 L, 188 R. As the fluid exits the channels 188 L, 188 R, the fluid path is altered by the angled inner surfaces flanking the channels 188 L, 188 R. The reaction causes the nozzle 120 to rotate. As a result, the fluid is expelled radially outward from fluid outlets 189 L, 189 R of the nozzle 120 , through the transverse opening 157 , and onto the inside surface of the enclosure such as the inner wall surface of a toilet bowl.
Turning now to FIGS. 16-18 , there is shown a perspective view of a second embodiment of a holder 320 in accordance with the invention. The holder 320 can delivering fluid to a conduit, such as fluid conduit 18 in FIG. 1A . As shown in FIG. 16 , the holder 320 houses a container 22 , which may be an aerosol container. The holder 320 includes a base 328 and a triggering device (not shown in FIG. 16 ) that is identical to the triggering device 30 of FIGS. 2 and 3 . The triggering device for the holder 320 includes a first flange that is located on one end of the triggering device and a second flange that is located on an opposite end of the triggering device as in the triggering device 30 of FIG. 3 .
The base 328 may be configured such that it is assembled from two parts: a front portion 328 a , and a back portion 328 b . The front portion 328 a adjoins with the back portion 328 b to form the base 328 as shown in FIG. 16 . The base 328 includes a base wall 329 and a hanger 331 . The base 328 includes a manifold 332 that is located near the bottom of the base 328 . The manifold 332 includes an inlet, an outlet, and a fitment, similar to the manifold 32 depicted in FIG. 6 . The inlet of the manifold 332 is in fluid communication with the outlet of the manifold 332 .
The container 22 is housed within the holder 320 by a retention mechanism. The container 22 may be an aerosol container with a valve stem 48 , as shown in FIG. 18 . The container 22 is assembled with a retainer 350 before housing the container 22 in the holder 320 . The container 22 and the retainer 350 create a refill that is assembled by placing the retainer 350 over the dome 52 of the container 22 . The retention mechanism also includes five equally spaced fingers 360 that extend upwardly from the bottom wall 362 of the base 328 . Each finger 360 includes a bottom section 366 and an upper section 368 that is angled inward toward the central longitudinal axis of the base 328 . The retention mechanism is not limited to five fingers, as any number of two or more fingers can work.
FIG. 17 shows the holder 320 during installation of a refill. A user holds onto the container 22 and advances the retainer 350 downward toward the fingers 360 . With continued downward movement, the upper section 368 of each finger 360 comes into contact with the sloped side wall 372 of the retainer 350 . This flexes the upper section 368 of each finger 360 away from the central longitudinal axis of the base 328 . With continued downward movement, the retainer 350 engages the manifold 332 with the valve stem 48 engaging the fitment of the manifold 332 , similar to the manifold 32 depicted in FIG. 6 .
Looking now at FIG. 18 , it can be explained what happens during attempted installation of the container 22 without the retainer 350 . A user would hold onto the container 22 and advance the container 22 downward toward the fingers 360 . However, because the retainer 350 is not available to flex the upper section 368 of each finger 360 away from the central longitudinal axis of the base 328 , a top edge 374 of each finger 360 enters a groove 378 between the dome 52 and the chime 376 of the container 22 . This prevents continued downward movement and therefore, the valve stem 48 of the container 22 cannot engage the fitment of the manifold 332 .
It can be appreciated that the retainer 350 and each finger 360 of the retention mechanism provide a means by which only a container 22 having the retainer 350 can be advanced such that the valve stem 48 of the container 22 engages the fitment of the manifold 332 . When a user attempts to install a container without the retainer 350 into the holder 320 , the fingers 360 prevent engagement of the valve stem 48 of the container 22 with the fitment of the manifold 332 . In this case, operation of the device is not possible as fluid cannot flow from the valve stem 48 to the manifold 332 .
Various cleaning and/or deodorizing chemicals are suitable for use with a toilet bowl cleaning device according to the invention. For example, mildly acidic and near neutral pH antimicrobial compositions such as those described in U.S. Pat. Nos. 6,471,974 and 6,162,371 can be advantageous when used with a toilet bowl cleaning device according to the invention. Alkaline antimicrobial toilet bowl cleaning formulations such as those described in U.S. Pat. No. 6,425,406 can also be advantageous. Acidic compositions such as those described in U.S. Pat. No. 6,812,196 may also be suitable. When using a steel container and acidic compositions, a steel container with a plastic liner or a bladder with a surrounding propellant may be desirable to minimize acidic corrosion of the steel container. Aluminum containers may also be an option for acidic compositions. The above chemicals are non-limiting illustrative examples of cleaning and/or deodorizing chemicals suitable for use with a toilet bowl cleaning device according to the invention. Other example suitable chemicals include, for example, enzymes, chelating agents, corrosives and amino acids.
Although the present invention has been described in detail with reference to certain embodiments, one skilled in the art will appreciate that the present invention can be practiced by other than the described embodiments, which have been presented for purposes of illustration and not of limitation. Therefore, the scope of the invention should not be limited to the description of the embodiments contained herein.
INDUSTRIAL APPLICABILITY
The present invention provides a toilet bowl cleaning device for spraying an inner surface of the toilet bowl, and/or the toilet water, and/or under the toilet rim with a cleaning and/or deodorizing chemical. The toilet bowl cleaning device includes a hand or foot actuated lever for releasing a fluid from the container into a fluid delivery system and a clip for mounting a fluid sprayer adjacent an inner wall of the toilet bowl.
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.
|
A device for spraying an inner surface of a toilet bowl with a cleaning and/or deodorizing chemical is disclosed. The device includes a container for the chemical, a container holder, a sprayer through which the chemical can be sprayed laterally at least halfway around a perimeter of the sprayer, means for attaching the sprayer near a rim of the toilet bowl, and a fluid conduit in fluid communication with the container and the sprayer. The toilet bowl cleaning device can include a hand or foot actuated lever for releasing a fluid from the container into a fluid delivery system, and a clip for mounting the sprayer adjacent an inner wall of the toilet bowl wherein the clip can be adjusted to fit different size toilet bowls.
| 4
|
RELATED APPLICATION
[0001] This is a divisional of patent application Ser. No. 10/094,691, filed on Mar. 11, 2002 by Steen B. Mikkelsen entitled “Automatic Waste-Area Removal Method” which was a continuation-in-part of now-abandoned patent application Ser. No. 09/804,344, filed on Mar. 12, 2001 by Steen B. Mikkelsen, entitled “Automatic Waste-Area Removal Method and Apparatus.”
FIELD OF THE INVENTION
[0002] This invention is related generally to decal laminate technology, such as is involved in the preparation of one or more decals (e.g., “graphic areas” or “product areas”) which are formed as part of a removable layer of a laminate for later removal and application onto various surfaces. More particularly, the invention relates to the field involving prior removal of waste portions of removable laminate layers, leaving the removable decal in place on the laminate.
BACKGROUND OF THE INVENTION
[0003] Many if not most decals are graphics-image-bearing portions (sometimes referred to herein as “product areas,” whether or not they have graphics images thereon) of a removable layer (sometimes referred to herein as a “face layer”) of a laminate. Each such decal laminate typically includes the face layer and a backing layer (or “liner”), the face layer being removably secured to the backing layer by an adhesive. The adhesive is preferential to the face layer, and is used, after removal of the product area(s) from the backing layer, for the adhesive attachment of the product area(s) of the face layer onto the surface intended to be covered—for decorative, signage or any of a multitude of other purposes.
[0004] To facilitate production of product areas (decals) in a form ready for use, it is frequently necessary or desirable to pre-remove the area or areas of the face layer which is/are not product areas from the backing layer of the decal laminate. (These non-product areas of the face layer are often referred to herein as “waste areas.”) Such pre-removal of waste areas leaves the product area(s) on the backing layer—ready to be easily peeled away from the backing layer just prior to use. The pre-removal of waste areas of a face layer, sometimes referred to “sheet-weeding,” greatly facilitates the subsequent removal of product areas (decals) just prior to use.
[0005] (The pre-removal of waste areas, of course, follows slitting or other severing of the product areas from the waste areas, which occurs while the removable layer to be slit or severed is in place on the backing layer. A highly preferred and advantageous method and apparatus for accurate severing around the product area or areas of the face layer of a decal laminate is disclosed in commonly-owned U.S. patent application Ser. No. 09/678,594, filed Oct. 4, 2000, entitled “Method and Apparatus for Precision Cutting and the Like of Graphics Areas from Sheets.”)
[0006] Sheet-weeding is typically carried out by nimble-fingered workers who delicately lift and peel away unused portions of the image-bearing face layer of a decal laminate. This is tedious and time-consuming work. Progress has been made toward automating the sheet-weeding process; despite such efforts, there remains a need for an improved automatic waste-area removal method and apparatus.
[0007] Various automated systems have been devised over the years for facilitating sheet-weeding operations. Among these are the systems and concepts disclosed in the following United States patents: U.S. Pat. No. 5,143,576 (Logan); U.S. Pat. No. 5,277,736 (Logan); U.S. Pat. No. 5,026,584 (Logan); U.S. Pat. No. 4,246,058 (Reed); U.S. Pat. No. 4,786,537 (Sasaki); U.S. Pat. No. 5,695,600 (Goin); and U.S. Pat. No. 4,333,781 (Meulenberg). These prior systems each have certain disadvantages or problems, some of which are set forth below.
[0008] The computer-controlled systems of the Logan patents use complex adhesive materials including microspheres or microcapsules which, when broken by force application, release strong adhesive to allow an overlay sheet to engage and remove portions of a sheet. Such adhesives can be very expensive, and force-activation can be problematic and difficult in high-speed operations.
[0009] The Reed disclosure involves an embossing of areas to be removed in order to weaken their adhesive attachment to the base layer and facilitate removal. However, such embossing tends to be a step which, among other things, may be unacceptable for removal of intricate waste areas or patterns around irregularly shaped decals or product areas.
[0010] The Sasaki disclosure involves removal of an overlayer after a separation is caused by radiation treatment of a radiation-responsive composition. This system is complex and believed not to be suitable for many high-speed production operations.
[0011] The prior systems and disclosures fall short of offering and delivering simple, effective sheet-weeding which is fully suitable for high-speed decal production and similar waste-area removal operations.
OBJECTS OF THE INVENTION
[0012] It is an object of this invention, in the field of decal laminate technology, to provide an improved sheet-weeding method and apparatus for prior removal of waste portions of removable laminate layers which overcomes some of the problems and shortcomings of the prior art.
[0013] Another object of this invention is to provide a sheet-weeder and sheet-weeding method which can operate at high speeds.
[0014] Another object is to provide a sheet-weeder which can operate with little or no detrimental effects to the product areas remaining on the laminate.
[0015] Another object of the invention is to provide a sheet-weeding method which more reliably removes all or nearly all of the waste areas of the face layer from the backing layer while more reliably not removing all or nearly all of the product areas.
[0016] Another object of the invention is to provide a sheet-weeding which allows reliable removal of waste areas of the face layer from the backing layer around delicate products areas.
[0017] Still another object of the invention is to provide a sheet-weeder which is simple, efficient and cost-effective.
[0018] Yet another object of the invention is to provide an improved method and apparatus for removal of select areas of less-than-all layers of a laminate which are useful in a wide variety of contexts and applications.
[0019] These and other objects of the invention will be apparent from the following descriptions and from the drawings.
SUMMARY OF THE INVENTION
[0020] The invention is a method and apparatus for removing waste area(s) of a face layer from a laminate composed of a backing layer with the face layer removably adhering thereto, while leaving at least one product area of the face layer in place on the backing layer. The sheet-weeding method of this invention includes applying an adhesive on portions of the waste area(s), temporarily adhering the laminate to a carrier surface (of a carrier-surface member) using the adhesive, and separating the laminate from the carrier surface with the waste area(s) remaining on the carrier surface.
[0021] A number of terms used herein are defined at the end of this “Summary” section. Such definitions should be referred to for clarity of understanding.
[0022] In certain highly preferred embodiments, the carrier-surface member is a carrier sheet—most preferably a carrier web. In such embodiments, the adhering step, in which the laminate is adhered to the carrier web or other carrier sheet, such combination is sometimes referred to herein as a “carrier lamination.” In some embodiments, such carrier lamination is discarded with the waste area(s) remaining on it. Suitable carrier web materials include unused newsprint. Embodiments using a carrier web facilitate continuous or nearly continuous sheet-weeding.
[0023] In preferred embodiments of the invention utilizing a carrier web, the process of separating the laminate from the carrier web while leaving the waste areas on the carrier web involves peeling the carrier web away from the laminate. In certain preferred embodiments, it is most preferred that the separating step include the step of pulling the carrier web over a separator edge in tension to initiate separation of the laminate from the carrier web.
[0024] As already indicated, the carrier-surface member is preferably in the form of a carrier web; however, in some embodiments it can be in the form of a fairly large cylindrical roller—sufficient to accommodate various operations therearound. When in the form of a carrier web, the carrier web may be a long continuous two-ended web, such as the newsprint mentioned above, or may be an endless web each portion of which is used and reused. In preferred embodiments in which the carrier-surface member is either an endless carrier web or a large cylindrical roller, the method of this invention preferably includes, after the step of separating the laminate from the carrier surface with the waste areas thereon, the further step of removing the waste areas from the carrier surface and discarding the waste areas, thereby clearing the carrier surface for reuse.
[0025] In certain embodiments of the invention, the adhesive is applied adjacent to the product area(s), preferably only at discrete locations. It is preferred that the adhesive applicator apply a quick-drying liquid adhesive, doing so by shooting the adhesive onto the specific locations of the waste area(s) without applicator contact with the waste area(s).
[0026] Certain preferred embodiments in which a carrier web is used include: unrolling a portion of the carrier web from a roll; performing the laminating of a laminate to the unrolled portion of the carrier web; separating the laminate from the unrolled portion; and thereafter rolling up the carrier web with the waste area(s) thereon.
[0027] In preferred embodiments of this type, the web is moving in a direction along its length at least during the laminating and separating steps. In these embodiments, the product and waste area(s) each have at least one leading-edge portion and at least one trailing-edge portion (see definitions infra), some of the leading-edge portion(s) of the waste area(s) being adjacent to trailing-edge portions of the product areas. In highly preferred embodiments, the adhesive is applied to the leading-edge portion(s) of the waste areas.
[0028] In preferred embodiments, the precise locations of adhesive application are controlled by a computer. Precise locations are determined by what is best to affect separation of waste areas while leaving product areas fully intact on the backing layer.
[0029] The apparatus of this invention includes: a support for the laminate; an adhesive applicator adjacent to the supported laminate; an actuator associated with the applicator; a controller for the actuator to cause application of an adhesive to the waste area(s); a carrier-surface having a carrier surface positioned to receive the laminate with the laminate adhering thereto; and a separator adjacent to the carrier surface to separate the laminate from the carrier surface with the waste area(s) remaining on the carrier surface.
[0030] Certain embodiments of such apparatus also include a stripper for removing the waste area(s) from the carrier surface after the separation has been accomplished. This allows the carrier surface, which is preferably endless, to be reused, and in some cases enhances the continuous nature of the operation.
[0031] Certain preferred forms of the apparatus of this invention include: a work surface on which to receive the laminate; at least one adhesive applicator mounted adjacent to the work surface; an actuator associated with the applicator(s); an actuator controller to cause application of an adhesive to predetermined portions of the waste area(s); a laminator beside the work surface including a supply of carrier web oriented for temporary lamination with the laminate using the applied adhesive; and a delaminator positioned to receive the carrier lamination and delaminate the laminate therefrom with the waste area(s) adhering to the carrier web.
[0032] In certain other highly preferred embodiments of such apparatus, as already indicated by the above discussion of the inventive method, the carrier-surface member is a carrier web. In such embodiments, it is most preferred that the separator include a separator edge positioned so that the carrier web passes under tension over the edge to initiate separation of the laminate from the carrier web.
[0033] In highly preferred embodiments of the invention, the face layer of the laminate has a plurality of registration marks at and about the product area(s) which are used for locating those areas of the laminate to which adhesive is to be applied. More specifically, the apparatus includes a controller (e.g., computer) programmed with information on the product area(s) and the waste area(s) and a sensor mounted adjacent to the work surface and capable of sensing locations of the registration marks and transmitting such information to the controller. The applicator(s) is/are actuated in response to the information about the locations of the registration marks sensed by the sensor and the information on the product area(s) and the waste area(s).
[0034] The laminates for which the method and apparatus of this invention facilitate sheet-weeding operations can be in various forms. For example, the laminates can be in the form of discrete sheets, either large or small, or a laminate may be in the form of a lengthy continuous sheet (web) which extends from a supply roll to a take-up roll. Either way, the laminates to be weeded may have a large number of product areas on it, in a great variety of shapes and sizes, and a great number of waste areas in a variety of shapes and sizes. In other cases, a lengthy continuous laminate web may have one or more rows of identically-shaped product areas such as labels or the like.
[0035] Broadly considered, this invention is a method for removing sub-areas of a face layer from a laminate composed of a backing layer with the sub-areas removably adhering thereto over less than all of the backing layer, and the invention involves: applying an adhesive on portions of the sub-areas; temporarily adhering the laminate to a carrier sheet using the adhesive; and separating the sub-areas from the backing layer by peeling them off with the carrier sheet.
[0036] In certain preferred embodiments of the method of this invention, one waste area has a leading edge portion with a leading edge that includes a lead part and at least one trailing lateral part, and the separating step includes (1) separating the waste area (with the carrier surface, e.g., a carrier sheet in web or other form) from the backing layer along the lead part before the trailing lateral part(s) are separated from the backing layer, thereby creating a chord line spanning the lead part, (2) continuing the separating step until the chord line substantially spans the leading edge portion, and (3) thereafter completing the separating step.
[0037] In such embodiments, it is preferred that the leading edge portion have at least one starter tab along the lead part of the leading edge, the starter tab extending in the direction opposite the weeding direction and having a width less than about 10% of the width of the leading edge portion.
[0038] In a highly preferred embodiment, the leading edge is convex. Preferably, such convex leading edge is a substantially circular arc having a radius greater than half the width of the leading edge portion. Such arc can be very gentle; even if the radius is substantially greater than the width of the leading edge portion to the point that the arc is nearly a straight line, waste area removal is substantially facilitated.
[0039] In certain other preferred embodiments of the method of this invention, in which a product area has a delicate leading edge portion, the waste area includes one trailing edge portion adjacent to the delicate leading edge portion, such trailing edge portion having a force-modifying slit therein which surrounds the delicate leading edge portion and has ends on opposite sides thereof.
[0040] In certain preferred embodiments having delicate leading edge portions, the ends of the force-modifying slit are downstream of the delicate leading edge portion. Preferably, the force-modifying slit is arcuate; the slit may be substantially circular. It is highly preferred that the ends of the force-modifying slit be downstream of the delicate leading edge portion.
[0041] In certain embodiments of the inventive method, a particularly delicate product areas is surrounded by a temporary product area such that the temporary product area is removed from the backing layer at some time following the completion of the automatic weeding process.
[0042] In certain embodiments the apparatus for removing sub-areas of a face layer sheet from a laminate of the type having been formed by removably adhering the face layer sheet to a backing layer, the sub-areas covering less than all of the backing layer, the face layer sheet having a plurality of registration marks at and about the sub-areas, comprises a sensor that senses locations of the plurality of registration marks; an adhesive applicator that automatically applies adhesive to portions of the sub-areas in response to the sensor sensing locations of the plurality of registration marks; a carrier-surface member having a carrier surface that receives the laminate with the laminate adhering thereto via the adhesive; and a separator adjacent to the carrier surface that separates the laminate from the carrier surface with the waste area(s) remaining on the carrier surface.
[0043] In certain embodiments, the separator peels the sub-areas from the backing layer. In certain embodiments, the apparatus further comprises a controller that actuates the adhesive applicator to apply adhesive on portions of the sub-areas in response to the sensor sensing the locations of the plurality of registration marks.
[0044] In certain embodiments, the applicator is a jet applicator which applies adhesive without applicator contact with the sub-areas. In certain embodiments, the adhesive is a quick-drying liquid.
[0045] In certain embodiments, the carrier surface forms an endless web. In certain embodiments, at least one product area is surrounded by a sub-area, the product area remaining on the backing layer during separation of the sub-area and the backing layer.
[0046] In certain embodiments, the laminate formed by removably adhering a face layer sheet to a backing layer, the laminate for use with an apparatus for removing sub-areas of the face layer sheet from the backing layer, the sub-areas covering less than all of the backing layer, to leave at least one product area of the face layer sheet in place on the backing layer, the laminate comprising the backing layer; and the face layer sheet, the face layer sheet having a plurality of registration marks at and about the sub-areas, the face layer sheet including the sub-areas, each sub-area having a leading edge portion with a leading edge having a lead part, at least one trailing lateral part and at least one starter tab along the lead part, the starter tab extending in the direction opposite a weeding direction and having a width less than about 10% of the width of the leading edge portion. Such a laminate provides that, during removal of the sub-areas from the backing layer, the lead parts are separated from the backing layer before the trailing lateral parts are separated from the backing layer, thereby creating chord lines that span the lead parts before substantially spanning the leading edge portions with removal of the sub-areas progressing along the weeding direction.
[0047] In certain embodiments, each leading edge has two lateral parts, one on each side of the respective lead part. In certain embodiments, each leading edge is convex. In certain embodiments, each leading edge is a substantially circular arc having a radius greater than half the width of the respective leading edge portion. In certain embodiments, each radius is greater than the width of the respective leading edge portion.
[0048] The invention also includes, in combination, a laminate and an apparatus for use with the laminate, the laminate formed by removably adhering a face layer sheet to a backing layer, the face layer sheet having sub-areas covering less than all of the backing layer, the face layer sheet having a plurality of registration marks at and about the sub-areas, the apparatus removing the sub-areas of the face layer sheet from the laminate to leave at least one product area of the face layer sheet in place on the backing layer.
[0049] In such a combination, the apparatus may comprise a sensor that senses locations of the plurality of registration marks; an adhesive applicator that automatically applies adhesive to portions of the sub-areas in response to the sensor sensing locations of the plurality of registration marks; a carrier-surface member having a carrier surface that receives the laminate with the laminate adhering thereto via the adhesive; and a separator adjacent to the carrier surface that separates the laminate from the carrier surface with the waste area(s) remaining on the carrier surface.
[0050] In such a combination the laminate may comprise the backing layer; and the face layer sheet in which each sub-area has a leading edge portion with a leading edge having a lead part, at least one trailing lateral part and at least one starter tab along the lead part, the starter tab extending in the direction opposite a weeding direction and having a width less than about 10% of the width of the leading edge portion.
[0051] Such a combination provides that, during removal of the sub-areas from the backing layer, the lead parts are separated from the backing layer before the trailing lateral parts are separated from the backing layer, thereby creating chord lines that span the lead parts before substantially spanning the leading edge portions with removal of the sub-areas progressing along the weeding direction.
[0052] As used herein, the following terms have the meanings given below, unless the context requires otherwise:
[0053] The term “quick-drying adhesive” refers to a liquid adhesive which, when applied by the applicator, flows in its liquid state easily enough to be applied with a jet applicator or sprayer but which, when applied to the waste areas of the face layer, dries rapidly enough such that it acts properly as an adhesive when it is contacted by the carrier-surface member.
[0054] The term “weeding direction” as used herein refers to the direction in which the weeding progresses along a sheet or roll of materia. More specifically, it refers to the direction of motion of the line along which separation of waste areas from the backing layer occurs. Accordingly, the weeding direction proceeds from “upstream” positions to “downstream” positions.
[0055] The terms “leading edge portion” and “trailing edge portion” pertain, e.g., to portions of areas of the face layer (i.e., portions of the product areas/or portions of the waste areas) in embodiments of this invention in which the carrier surface (e.g., the surface of a carrier web) is moving during the adhering and separating (or “laminating” and “delaminating”) steps of the sheet-weeding process. A leading edge portion of a waste area is a part thereof which is (1) immediately adjacent to and following a product area as determined along lines parallel to the weeding direction or (2) is immediately adjacent to a leading edge of the laminate if such leading edge is part of a waste area of the laminate. A trailing edge portion of a product area is a part of thereof which is immediately adjacent to and ahead of a waste area as determined along lines parallel to the weeding direction. In embodiments not involving a moving carrier web, the terms “leading edge portion” and “trailing edge portion” refer to the order of portions undergoing separation—with a “leading portion” always being encountered before a “trailing portion.”
[0056] The term “leading edge” as used herein with respect to a waste area refers to the line along the farthest upstream boundary of the leading edge portion of such waste area.
[0057] The term “width” as used herein with respect to a waste area refers to a dimensional measurement taken across the waste area in a direction substantially perpendicular to the weeding direction.
[0058] The term “chord line” as used herein refers to the line along which separation of a waste area from the backing layer takes place, with the length of the chord line being equal to the length of the continuous portion of the waste area being separated from the backing layer. Thus, if the weeding process is occurring across a wide sheet of laminate, it is possible that there could be more than one “chord line” defined locally along the line of separation.
[0059] The term “force ratio” as used herein refers to the ratio of “adhering forces” to “pulling forces” on a portion of face layer. With respect to portions of a waste area which are to be separated from the backing layer, “adhering forces” include both (1) the holding force of the adhesive layer (between the face layer and the backing layer of the laminate material) and (2) any additional forces from the surrounding face layer (i.e., the force exerted on the portion of waste area by the surrounding product area from incomplete slitting of the face layer and/or the adhesive layer and/or from rejoining of portions of the adhesive layer on either side of the slit) which are holding the portion of the waste area in place, and “pulling forces” are adhesive forces between the waste areas and the carrier surface from the adhesive applied the waste areas. With respect to portions of a product area (not intended to be separated from backing layer), “adhering forces” are the force applied by the adhesive layer between the face layer and the backing layer of the laminate material, and “pulling forces” include both (1) the force exerted on the portion of the product area by the surrounding waste area being removed from around the portion of the product area (i.e., similar to the forces from surrounding waste area described above) and (2) any small forces which might occur from the contact of the carrier surface with the portion of the product area. (These force considerations are of course qualitative in nature and imply consistent bases of determination, whatever they may be—e.g., taking into consideration both normal forces and shear forces.)
[0060] The term “delicate leading edge portion” as used herein with respect to a product area refers to a portion of the product area for which the force ratio is approximately one or less than one and which has a dimension along the weeding direction. Thus, delicate leading edge portions of product areas are susceptible to unwanted separation from the backing layer unless the force ratio is raised. Examples of delicate leading edge portions of product areas include pointed leading edge portions such as the points of a star or small shapes such as letters.
[0061] The term “force-modifying slit” as used herein refers to cuts made in the trailing edge portion of a waste area adjacent to and surrounding a delicate leading edge portion of a product area to change the force ratio of the portion of the product area.
[0062] The term “starter tab” as used herein refers to small areas of waste area added to leading edge portions of waste area and extending in the upstream direction from the leading edge portion in order to change the force ratio of the leading edge portion of waste area, thereby enabling initiation of the separation of the waste area from the backing layer.
[0063] The term “particularly delicate product area” as used herein refers to entire product areas which are characterized by a low force ratio.
[0064] The term “temporary product area” as used herein refers to a small area of waste area which is not separated from around particularly delicate product areas and which are separated from the backing layer by hand after completion of the automatic weeding process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0065] The drawings illustrate preferred embodiments which include the above-noted characteristics and features of the invention. The invention will be readily understood from the descriptions and drawings. In the drawings:
[0066] FIG. 1 is a highly schematic, fragmentary perspective view (not to scale) of an apparatus in accordance with this invention. In particular, the thicknesses of the laminate layers and carrier web are greatly exaggerated to help illustrate the principles of this invention.
[0067] FIG. 2 is a schematic, fragmentary perspective view of a laminate, including product areas and a surrounding waste area, such laminate again being illustrated out of scale as to thickness.
[0068] FIG. 3 is a schematic, side elevation of an adhesive applicator adjacent to a laminate (to be weeded) on a support surface. The laminate is again illustrated out of scale as to thickness.
[0069] FIG. 4 is a schematic, fragmentary perspective view of FIG. 3 . The laminate is again illustrated out of scale as to thickness.
[0070] FIG. 5 is a schematic side elevation of an endless carrier web and its associated separator edge and waste-area stripper. The laminate and carrier web are again illustrated out of scale as to thickness.
[0071] FIG. 6 is a schematic fragmentary plan view of the arrangement of parts of a sensing and adhesive applicator apparatus of a preferred embodiment of this invention, such sensing and applicator apparatus having multiple sensors and multiple jet applicators for adhesive.
[0072] FIG. 7 is a schematic side elevation representing an alternative applicator apparatus for application of adhesive on intended portions of waste areas to be removed. Once again, the laminate is illustrated far out of scale as to thickness.
[0073] FIG. 8 a is a top view of a portion of a sheet of laminate illustrating a waste area leading edge portion which is perpendicular to the weeding direction.
[0074] FIG. 8 b is a top view of a portion of a sheet of laminate illustrating a preferred force-modifying feature included in a preferred shape of a waste area leading edge portion.
[0075] FIG. 9 is a top view of a portion of a sheet of laminate illustrating a force-modifying feature placed near a trailing edge portion of a waste area adjacent to a leading edge of a delicate feature of a product area.
[0076] FIGS. 10 a and 10 b are enlarged portions of FIG. 9 .
[0077] FIG. 11 is a top view of a particularly delicate product area surrounded by a temporary product area.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0078] Before describing sheet-weeding apparatus 10 and its various elements, which should be understood to be represented in highly schematic fashion, it will be helpful to describe the laminate upon which sheet-weeding apparatus 10 is operating and to illustrate some of the terms used to describe the sheet-weeder operation. Referring to FIG. 2 , the laminate 50 a discrete sheet made up of multiple layers, including face layer 52 , adhesive layer 54 , and backing layer 56 . FIGS. 1 and 3 - 7 also include illustrations of laminate sheet or sheets 50 with face layer 52 , adhesive layer 54 , and backing layer 56 .
[0079] Referring again to FIG. 2 , face layer 52 has been slit (severed), with the slit lines isolating product areas 58 from waste areas 60 . Product areas 58 are shown in simple form; in many cases, the shapes of product areas may be very complex or intricate, and may have islands of waste areas within them. When waste areas 60 are weeded from laminate sheet 50 , products areas 58 remain on backing layer 56 for their eventual intended use.
[0080] FIG. 2 further illustrates the leading and trailing edges of both product areas 58 and waste areas 60 . If motion of laminate sheet 50 is assumed to be left to right as indicated in FIG. 2 , then the location of a leading edge 68 of waste area 60 is as indicated. In similar fashion, a trailing edge 70 of a product area 58 , a leading edge 64 of a product area 58 , and a trailing edge 66 of a waste area 60 are indicated in FIG. 2 .
[0081] FIG. 2 further illustrates discrete locations 62 of adhesive 72 applied to waste areas 60 of face layer 52 . Adhesive 72 can be one of various quick-drying adhesives which are known in the art. Acceptable choices would be known to those skilled in the art and who are made aware of this invention. One group of adhesives which are useful are permanent waterborne acrylic pressure-sensitive adhesives available from ICI Americas Inc., New York, N.Y.
[0082] Referring to FIGS. 3 and 4 , adhesive applicator 76 is positioned over discrete locations 62 on face layer 52 and applies adhesive 72 to discrete locations 62 . As shown in FIGS. 3 and 4 , adhesive applicator 76 does not make contact with face layer 52 of laminate sheet 50 , but applies adhesive 72 by rapidly and accurately shooting small quantities of adhesive 72 in the form of droplets or spray 74 . Applicators suitable for use as adhesive applicator 76 , such as a jet or sprayer, are known in the art. FIG. 4 further illustrates a work surface 12 adjacent to applicator 76 for receiving laminate sheets 50 . FIGS. 6 and 7 , described further below, illustrate alternative devices for adhesive application.
[0083] Referring now to FIG. 1 , which illustrates a much larger portion of inventive sheet-weeding apparatus 10 , the embodiment shown is of the type which incorporates a carrier-surface member in the form of a carrier web 14 and in which carrier web 14 is moving in apparatus 10 in a direction along its length.
[0084] In FIG. 1 , laminate sheets 50 and carrier web 14 are moving from right to left through apparatus 10 . As a laminate sheet 50 moves from right to left, laminate sheet 50 is at first received and supported by support by work surface 12 . Adhesive applicator 76 is mounted adjacent to work surface 12 on an actuator apparatus 36 . Actuator apparatus 36 includes an actuator frame 38 and an actuator bar 40 , and is configured and arranged such that adhesive applicator 76 can be moved back and forth along actuator bar 40 and actuator bar 40 can be moved back and forth along actuator frame 38 , all under computer control as referred to below. In this way, any point on face layer 52 is available to receive adhesive 72 . It should be noted that a plurality of applicators can be associated with one or more actuator apparatuses.
[0085] Still referring to FIG. 1 , a sensor 78 is also adjacent to work surface 12 and is mounted such that it can be moved back and forth along actuator bar 40 along with adhesive applicator 76 . Sensor 78 is responsive to registration marks 44 . Sensor 78 , actuator apparatus 36 , and applicator 76 are connected to controller 46 through controller cable 48 . Controller 46 is a computer programmed with information on product areas 58 and waste areas 60 such that the position of product areas 58 and waste areas 60 on work surface 12 enable actuator 36 to respond to controller 46 to move applicator 76 to the desired locations on face layer 52 and apply the precise amount of adhesive 72 to face layer 52 .
[0086] Carrier web 14 is unrolled from a carrier web supply roll 16 and temporarily laminated with laminate sheet 50 by passing through a laminator, which includes a face layer laminator roller 18 and a backing layer laminator roller 20 . The temporary lamination formed by laminator rollers 18 and 20 is held together by applied adhesive 72 , and is referred to as a carrier lamination 24 . Carrier lamination 24 is in tension as carrier lamination 24 is received by a delaminator 26 , which includes a separator edge 28 and a retaining bar 30 . Separator edge 28 has a tightly-rounded leading edge 32 which is shaped such that waste areas 60 are lifted off backing layer 56 as carrier lamination 24 passes over leading edge 32 . Retaining bar 30 of delaminator 26 is positioned such that product areas 58 are prevented from being lifted up as carrier lamination 24 passes over separator edge 32 .
[0087] After passing through delaminator 26 , waste areas 60 remain adhered to carrier web 14 by adhesive 72 , and product areas 58 remain on backing layer 56 for later use as intended. The weeded laminates are collected in a pile, ready for use.
[0088] Carrier web 14 , with waste areas 60 remaining on it, is taken up by a carrier web take-up roller 34 . When carrier web take-up roller 34 is full, it can be discarded and replaced with an empty roller. Carrier web 14 is preferably low-cost newsprint or the like.
[0089] As is by now apparent, FIG. 1 illustrates two laminate sheets 50 , the first one (to the left in FIG. 1 ) undergoing separation after adhering to carrier web 14 and the second one (to the right in FIG. 1 ) having adhesive applied to its waste areas. It should be noted that, instead of being in the form of discrete sheets, the laminate could be in the form of a continuous laminate web. In such case, after weeding the weeded web, with its product areas ready for use, would itself be wound onto a take-up roller.
[0090] Referring again now to the second (the rightmost) laminate sheet shown in FIG. 1 , such laminate sheet (like that before it) has a waste area along its leading edge and illustrates adhesive having been applied to a leading edge portion of such waste area. It should also be noted that, with respect to product area 58 as seen on the second laminate sheet in FIG. 1 , adhesive is being applied all around the perimeter of product area 50 . With respect to adhesive application at portions of waste areas around product areas, FIG. 6 , discussed more below, serves to illustrate the application of adhesive only at leading portions of waste areas around product areas.
[0091] FIG. 5 illustrates schematically a portion of another sheet-weeder apparatus 90 incorporating a carrier-surface member 80 which is in the form of an endless carrier web. Apparatus 90 also includes a separator edge 28 and a stripper 82 . In similar fashion to apparatus 10 of FIG. 1 , laminate sheet 50 and endless carrier web 80 move between a face layer laminator roller 18 and a backing layer laminator roller 20 to form a temporary carrier lamination 24 .
[0092] Also in similar fashion to apparatus 10 of FIG. 1 , separator edge 28 of apparatus 90 facilitates the lifting of waste areas 60 from backing layer 56 , leaving product areas 58 on backing layer 56 for later use as intended, while waste areas 60 remain adhered to endless carrier web 80 . Unlike apparatus 10 of FIG. 1 , however, waste areas 60 which remain on endless carrier web 80 are removed from endless carrier web 80 by stripper 82 , immediately freeing that portion of endless carrier web 80 for reuse. Stripper 82 incorporates a knife edge 86 which scrapes waste areas 60 from endless carrier web 80 and discards them into a waste bin 84 .
[0093] Alternative strippers can include apparatus which applies heat (or removes heat, i.e., makes cold) in order to soften (or harden) the adhesive and release, or at least facilitate release of, waste areas from the endless carrier web or other carrier-surface member. Depending on the particular location along the endless carrier web (or other carrier-surface member) and depending on the type of adhesive used, differing temperature levels may be used to accomplish the adhering or releasing of laminate layers. Alternatives for the waste bin can include, e.g., a take-up roller to collect continuous waste areas removed from the endless carrier web by the stripper or a chopper and a conveyor to discard large amounts of waste material.
[0094] Precise application of adhesive to waste areas for sheet-weeding purposes depends on accurate information about the locations of product areas and waste areas. There are numerous ways in which such locations can be determined. Highly preferred ways involve the sensing of registration marks 44 . For example, sensors can be in a line as is common in a computer scanner and either be fixed to a frame or free to move. Another alternative is that sensor 78 and applicator 76 can be moved independently to speed up operation of apparatus 10 .
[0095] Referring now to the actuator apparatus with which one or more adhesive applicators are associated (for its/their control), the actuator apparatus can be designed to move the applicator(s) (and/or sensors) along three axes (rather just the two illustrated in FIG. 1 ) to give added flexibility and capability to the sheet-weeding apparatus.
[0096] Referring to the pattern of adhesive application, adhesive may be applied in discrete locations as illustrated, or can be applied in line segments, continuous lines, or even in wide areas as appropriate to the particular sheet-weeding application. This can include the entire surface of the waste area or areas. One preferred pattern, as illustrated by the rightmost product area of FIG. 2 , involves application of adhesive on waste areas just beyond all of the edges of the product areas. Another pattern can be continuous lines along the length of the laminate—e.g., to remove waste areas along the edges of the laminate, such as in the production of pressure-sensitive labels.
[0097] FIG. 6 illustrates schematically a highly preferred location sensing and adhesive-application apparatus 92 having several sensing and adhesive-applicator units 94 arranged side by side in a line across laminate. Sensing/applicator units 94 need not move in order to sense the locations of registration marks 44 or to apply adhesive in the proper locations on the two laminate sheets 50 that are shown in FIG. 6 . Instead, based on their sensing and the rate of movement of laminate sheets 50 , the adhesive applicators of sensing/applicator units 94 apply adhesive 72 at the proper time to be applied to discrete locations 62 , which are the locations programmed to be appropriate to facilitate the later separating step. FIG. 6 also serves to illustrate the preferred application of adhesive on various selected leading edge portions 68 of the waste areas 60 of two discrete laminate sheets 50 , as the laminate sheets pass sensing and adhesive-application apparatus 92 .
[0098] FIG. 7 illustrates another alternative adhesive-application apparatus 95 , in this case an applicator which applies adhesive by direct contact with face layer 52 of laminate sheet 50 . Adhesive application apparatus 95 applies adhesive 96 by means of an applicator roller 97 that has contact members 98 positioned to engage face layer 52 at the intended portions of its waste areas. Contact members 98 of applicator roller 97 receive adhesive 96 via transfer rollers 99 , and deposit such adhesive upon contact with face layer 52 . A variety of other adhesive applicator devices can be used in the apparatus of this invention.
[0099] FIGS. 8 a and 8 b illustrate an additional aspect of the inventive method wherein the leading edge of a waste area 60 is configured to facilitate more efficient and reliable removal of waste area 60 from the backing layer of the laminate. Waste area 60 surrounds product areas 58 . In FIG. 8 a , a leading edge portion 110 of waste area 60 is substantially perpendicular to the weeding direction. As the separation process progresses along laminate sheet 50 , the line of separation (not shown) reaches the leading edge 111 of leading edge portion 110 , and a pulling force is applied to leading edge portion 110 through adhesive 72 (shown as deposited at a series of discrete locations across leading edge portion 110 ). Since leading edge 111 is perpendicular to the weeding direction, the total force required to cause separation suddenly increases as the line of separation reaches leading edge portion 110 . Depending on a number of variables such as the nature of the various material surfaces and the adhesive strengths of adhesive 72 and the adhesive layer of the laminate, the force ratio may be too high, thus preventing leading edge portion 110 from separating cleanly from the backing layer.
[0100] FIG. 8 b illustrates a preferred embodiment of the inventive method which lowers the force ratio, thereby enabling efficient and reliable separation of waste area from backing layer. The leading edge 113 of a leading edge portion 112 is given a slightly convex shape, thereby dividing leading edge 113 into a lead part 114 and two trailing lateral parts 116 a and 116 b . (The approximate width of parts 114 , 116 a , and 116 b are indicated in FIG. 8 b by the brackets drawn upstream of leading edge 113 .) As the line of separation progresses along sheet 50 , the line of separation reaches lead part 114 prior to reaching trailing lateral parts 116 a and 116 b . The length of the chord line across leading edge portion 112 gradually increases in length as the line of separation moves along sheet 50 in the weeding direction, thereby lowering the force ratio at the initiation of separation of waste area 60 and gradually raising the total force required to separate leading edge portion 112 from backing layer as the separation progresses.
[0101] FIG. 8 b also illustrates a highly preferred embodiment of leading edge portion 112 . Starter tabs 100 (three shown), extending in a substantially upstream direction from lead part 114 , are added to leading edge portion 112 along lead part 114 of leading edge 113 . Starter tabs 100 lower the force required to initiate separation as the line of separation encounters leading edge portion 113 , thereby further increasing the efficiency and reliability of the separation process.
[0102] FIG. 9 illustrates another highly preferred embodiment of the inventive method. Sheet 50 is shown with waste area 60 and product areas 58 a , 58 b , 58 c , and 58 d , with each such product area having delicate leading edge portions 59 a , 59 b , 59 c , and 59 d respectively. Force-modifying slits 102 a , 102 b , 102 c , and 102 d surround delicate leading edge portions 59 a , 59 b , 59 c , and 59 d respectively. FIGS. 10 a and 10 b provide enlarged views of product areas 58 a and 58 d respectively. Trailing edge portions 120 and 122 are adjacent to delicate leading edge portions 59 a and 59 d respectively, with trailing edge portions 120 and 122 having force-modifying slits 102 a and 102 d respectively. (Trailing edge portions 120 and 122 are each shown with multiple indicators to illustrate that trailing edge portions 120 and 122 are areas of waste area which surround delicate leading edge portions 59 a and 59 d respectively.) In FIG. 10 a , force-modifying slit 102 a is positioned such that the end points 104 a and 104 b of slit 102 a are on opposite sides of delicate leading edge portion 59 a . As the line of separation progresses along sheet 50 in the weeding direction reaching the upstream portion of slit 102 a at trailing edge portion 120 , slit 102 a allows trailing edge portion 120 to temporarily remain on the backing layer until the line of separation progresses to end points 104 a and 104 b . At this time, the force ratio for delicate leading edge portion 59 a is high enough to cause separation of trailing edge portion 120 from the backing layer without causing delicate leading edge portion 59 a to be separated from the backing layer.
[0103] FIG. 10 b illustrates delicate leading edge portion 59 d , having an even sharper point than delicate leading portion 59 a . In similar fashion to events described in FIG. 10 a , separation of delicate leading edge portion 59 d is prevented. End points 106 a and 106 b of slit 102 d are comparatively farther downstream than endpoints 104 a and 104 b , thus accommodating the increased sharpness of delicate leading edge portion 59 d.
[0104] FIG. 11 illustrates another embodiment of the inventive method in which a temporary product area surrounds a particularly delicate product area. Sheet 50 is shown with waste area 60 surrounding a temporary product area 132 which surrounds a particularly delicate product area 130 . In situations for which the force ratio for an entire product area is near or less than one, such as is illustrated by particularly delicate product area 130 , temporary product area 132 is not separated from the backing layer by the automatic weeding process but is removed by manual weeding after the completion of the automatic weeding process. While the principles of this invention have been described in connection with specific embodiments, it should be understood clearly that these descriptions are made only by way of example and are not intended to limit the scope of the invention.
|
An apparatus and laminate allow removal of at least one sub-area of a face layer sheet from a laminate composed of a backing layer with the face layer sheet adhering thereto to leave at least one product area of the face layer sheet in place on the backing layer. The apparatus may comprise a work surface for receiving the laminate thereon; at least one adhesive applicator mounted adjacent to the work surface; an actuator associated with the applicator(s); an actuator controller to cause application of an adhesive to predetermined portions of the waste area(s); a laminator beside the work surface including a supply of carrier web oriented for temporary lamination with the laminate using the applied adhesive; and a delaminator positioned to receive the carrier lamination and delaminate the laminate therefrom with the waste area(s) adhering to the carrier web.
| 8
|
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.